hebel supercrete aws design guide

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Acoustic Wall Systems Design Guide AWS 2009 Version 1.1 NONTOXIC ENERGY SAVING LIGHT WEIGHT NOISE RESISTANT FIRE RESISTANT ACCURATE VERSATILE LONG LIFE RAPID ASSEMBLY EASILY WORKED BREATHABLE Coatings Ltd

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Page 1: Hebel Supercrete AWS Design Guide

Acoustic Wall SystemsDesign Guide

AWS 2009 Version 1.1

NONTOXIC ENERGYSAVING

LIGHTWEIGHT

NOISERESISTANT

FIRERESISTANT

ACCURATE VERSATILE LONG LIFE RAPIDASSEMBLY

EASILYWORKED

BREATHABLE

Coatings Ltd

Page 2: Hebel Supercrete AWS Design Guide

AWS 2009 2

Contents1.0 Introduction 3

1.1 What are Hebel Supercrete Acoustic Wall Systems? 3 1.2 Why choose AWS? 3 1.3 Availability 3 1.4 Panel sizes 4

2.0 Benefits 5

3.0 Acoustic Performance 6 3.1 Definitions 6 3.2 NZ Building Code Requirements 6 3.3 Acoustic Analysis 6

4.0 Selection of AWS Type 7

5.0 Fire Rating Performance 15 5.1 Fire Resistance Rating (FRR) of AWS Walls 15 5.2 System Variations 15

6.0 Structural Performance 16 6.1 Structural Performance 16 6.2 High Lateral Loading 16 6.3 Wall Heights 16 6.4 Cutting of Hebel Supercrete Panel 16 6.5 Steel Stud Frame 16 6.6 Custom Hebel Supercrete Panel 17 6.7 Fastenings 17 6.8 Lightweight Support Framing 17

7.0 Design & Installation Considerations 17

8.0 System Components 18

9.0 Installation of AWS Walls 20

10.0 Panel Handling 22

11.0 Delivery & Storage 23

12.0 AWS Construction Details 24 12.1 Hebel Supercrete Panel

Construction Details 24 12.2 Junction Details 27 12.3 Roof Details 29 12.4 Control Joint Details 30 12.5 Wet Area Wall Details 30 12.6 Door Details 31 12.7 Penetration and Services Details 32

Appendix A: A1 Hebel Supercrete Panel Material Properties 33 A2 Proforma Architectural Specification 34 A3 Installation Checklist 35

Health and Safety, Performance & Certification, Guarantee & Disclaimer 36

AWS 20092

Acoustic Wall SystemsDesign and Installation guideThis Design and Installation Guide is for acoustic wall panel systems, used primarily for intertenancy walls. However, the increasing popularity of home theatre systems is also generating a requirement for acoustic walls in residential homes. The options detailed in this design guide are suitable for single or multiple occupant residential or commercial use.

The design of acoustic walls is a specialized field and normally requires the services of a professional consultant. This guide has been prepared for their assistance but in no way replaces the services of a professional consultant on the project.

Page 3: Hebel Supercrete AWS Design Guide

AWS 20093

1.0 Introduction1.1 What are Hebel Supercrete Acoustic Wall Systems?Hebel Supercrete Acoustic Wall Systems (AWS) have been developed to satisfy the ever increasing demand for noise abatement in residential and commercial applications. They are based on the use of 75 mm thick Hebel Supercrete Panel, with or without various combinations of steel framing, lining and supplementary insulation, depending on the acoustic requirement of the wall. These are used to create wall systems which have minimal components and are relatively compact. The resulting walls exhibit high acoustic insulation performance, proven by both laboratory testing and successful applications throughout Australia and New Zealand.

There are four basic wall systems detailed in this guide which all equal or exceed the requirements of the New Zealand Building Code (NZBC). Wall systems with lesser acoustic performance have not been included. Any of the systems can be varied to suit individual requirements.

Hebel Supercrete Panels are made from Autoclaved Aerated Concrete (AAC), manufactured from sand, lime and cement, to which a gas forming agent, in the form of aluminum paste, is added. The liberated gas expands the mixture, forming small finely dispersed air bubbles, resulting in a lightweight concrete approximately one quarter of the weight of traditional concrete. It has a dry density of 500 kg/m3 (density at 30 % moisture content is 680 kg/m3)

The AAC is cast in 6.0 x 1.5 x 0.6 m blocks with reinforcing cages held in the correct place for individual panels. This block is then sliced with taught steel wires after the initial set, and the whole block is then cured and crystallized in an autoclave.

1.2 Why choose AWS?There are many different ways of creating an acoustic barrier between adjoining tenancies, which will meet New Zealand Building Code minimum requirements. Selection of the appropriate acoustic wall system can also depend on the required fire resistance rating and whether the system must be load bearing or have bracing capacity. Overall wall thickness can also govern the choice of wall system. Often, the acoustic rating desired will be more than the minimum code requirement.

Many building owners are disappointed with the performance of buildings constructed with only the minimum acoustic insulation and it is often difficult to increase the acoustic insulation retrospectively. Walls

constructed to the bare minimum are usually lower in cost, but represent poor value for money.

Some common systems consist of double timber or steel frames lined with fire resistant plasterboards, others are solid masonry or concrete tilt slab type construction. Timber framed solutions generally have lower fire ratings as they are combustible and wholly reliant on the lining to protect the frame. Steel frames also have low resistance to heat and can buckle under load. Lower fire rated walls may require sprinkler systems within the structure, and although these help protect human life, the end result of a fire in such a structure often means that the framed wall must be completely replaced after such an event. Also, these double frames and their multiple linings can take up a lot of floor space, frequently over 300 mm in width.

Masonry and dense concrete walls are slow to construct, and heavy, adding mass and bracing demand to the structure. They need additional strapping, lining and insulation to achieve minimum acoustic requirements. Tilt slabs are difficult to install between existing floor slabs, because of their large size, shape and weight.

The Hebel Supercrete Acoustic Wall Systems (AWS) overcome these inherent difficulties in achieving a high performance intertenancy partition. The Hebel Supercrete systems are slender, fire rated, with fast construction times, and with sound transmission reductions that exceed the NZ Building Code requirement. Hebel Supercrete panels are non combustible and provide 3 hour fire ratings. They are only one quarter of the weight of dense concrete and are easily manhandled into place. They can be easily cut on site making installation around beams, ducts and services much simpler than conventional dense concrete tilt slabs.

The systems selected for this design guide are practical, economic solutions for walls requiring excellent acoustic performance and fire protection.

1.3 AvailabilityHebel Supercrete Panel is manufactured by CSR Hebel Australia in a factory at Somersby, north of Sydney. CFG Concrete Ltd is the sole importer of Hebel Supercrete Panel into New Zealand, and has a network of distributors throughout the country for supply, liaison and backup support. Refer to the CFG Concrete Ltd website (www.hebel.co.nz) for your nearest distributor.

Because of the bulk quantities of panels purchased by CFG Concrete Ltd, the landed price in New Zealand is often less than similar panels purchased in Australia, and are hence priced very competitively.

Page 4: Hebel Supercrete AWS Design Guide

AWS 2009 4

1.4 Panel SizesAll 75 mm Hebel Supercrete Panel is manufactured in standard widths of 600 mm with a plain edge profile. Panels are available in several lengths between 2.4 and 3.0 metres. See Table 8.2 for available sizes. Panels can be easily site cut for other heights, widths, complex shapes, or services.

For walls higher than 3.0 metres, custom panel can be manufactured up to a 3.9 metre height in the 75 mm thickness. 100 mm panel is also available in 600 mm or 450 mm width and lengths up to 3.2 metres for specific designs – refer to CFG Concrete Ltd. Custom panels can have a tongue and groove edge profile. Note that there is a longer lead time required on custom panel as these are manufactured specifically for each design.

Fig. 1.2 Hebel Supercrete Panel is easily handled by two people in this Type 3 application

Figure 1.3 Hebel Supercrete Panel installed on the ground floor of an intertenancy wall in a Type 1 Wall

Fig. 1.5 Awaiting installation of base track and panels for second storey of intertenancy wall in Type 1 Wall

Fig. 1.4 Second storey panel installation in a Type 1 Wall

Fig 1.1 Hebel Supercrete Panel Trolley makes on-site manoeuvring quick and simple.

Page 5: Hebel Supercrete AWS Design Guide

AWS 20095

2.0 Benefits

Elma Apartments Metropole Apartments Harbour Watch Apartments

Mariners Cove The Vie Apartments

The many benefits of using Hebel Supercrete AWS systems include:

■ Acoustic Performance: Significantly reduced sound transmission between units and rooms.

■ Good Impact Noise Resistance: All Hebel Supercrete AWS walls have good impact noise resistance due to separated wall construction.

■ Lightweight: Lighter loads on structures compared to masonry block, for equivalent STC rating.

■ Slender Walls: Wall thicknesses range from 171 to 256 mm.

■ Cost Effective: Cost savings compared to traditional masonry construction.

■ No Wet Trades: Less mess and a cleaner, safer work area.

■ Less Wastage: Greatly reduced waste, as panels are available in a range of standard lengths. This allows for best-suited panel length selection, which eliminates or reduces off-cut waste. For a small price premium panels can be manufactured to specific lengths for large scale projects.

■ Speed of Construction: Fast installation and assembly speeds with smaller construction crew requirements.

■ Fire Protection: AWS systems have excellent fire rating properties and can achieve the highest code rating of 4 hours.

■ Security: Steel reinforced AAC panels provide a high degree of security between units.

■ Thermal Resistance: Excellent thermal insulation for energy savings between adjacent rooms.

■ Design Flexibility: Lighter weight allows increased spans, reduced column sizes and/or reduced beam depths. Ease of cutting allows complex shapes to be acoustically isolated.

■ Technical Support: Competent technical staff can assist with systems information.

The photos below show some of the projects that have used Hebel Supercrete AWS walls internally.

Page 6: Hebel Supercrete AWS Design Guide

AWS 2009 6

3.0 Acoustic Performance3.1 DefinitionsThere are a number of rating systems for defining the effectiveness of a wall for sound insulation. The New Zealand Building Code uses the Sound Transmission Class (STC) but some other regulatory authorities use the Weighted Sound Reduction Index (Rw).

Sound Transmission Class – STC

The STC value is a single number used to rate acoustic walls based on tests in an acoustic laboratory, where a test wall is constructed between two rooms that are acoustically isolated from each other. A sound is generated in one room and the sound level in the other room is measured, for frequencies between 100 Hz and 5000 Hz. The sound level differences are then normalized to allow for differences in various parts of the receiving room and for the absorption factor in the walls. These normalized values at each frequency band are compared to standard performance graphs where only a limited portion of the graph of sound loss is permitted to fall below the standard curve and the class is given by the highest standard contour line which is the best fit to the tested curve. The STC value is given by the value at 500 Hz on the best fit curve. Effectively, it is the expected loss in decibels through the wall under laboratory conditions. In reality, actual sound reduction in site conditions is usually less than the STC value due to flanking sound paths and other factors. The NZBC allows a 5 decibel reduction from the STC laboratory rating under site conditions. The STC is the system developed by the American Society for Testing and Materials (ASTM International).

Weighted Sound Reduction Index – Rw

The Rw is a weighted STC value where a correction factor is added to the STC value to take into account performance at lower frequencies. The Rw is a European system and is not currently used in the NZBC, but it is gaining acceptance in many other countries. Typically, the Rw value is one or two decibels less than the STC value, as the correction factor is usually negative.

Impact Isolation Class (IIC)

The IIC is usually used for floors only, but can be applied to walls. It quantifies the transmission of impact sound through a floor or wall. The test involves measuring the sound loss through a panel in a similar test setup as for the airborne sound in the STC test, but where the sound on one side is generated by a standard tapping machine. Higher numbers indicate less sound is being transmitted. The IIC is an American system which is gradually being replaced by the Ln,w value which is the ISO equivalent, but the NZBC at time of printing, still uses the IIC.

Acoustic Opinions

Sound Transmission Classes for specific configurations of walls are determined by professional acoustic consultants from computer models based on available test data with a 96% confidence of being within 2.5 decibels of a tested wall. These results are referred to as “opinions” as it is unrealistic to test every possible wall configuration.

Figure 13: “Best Fit” of Wall Test Result to Standardised Curves(STC 60 standardised curve is the highest curve fitting the results)

1/3 Octave Band Centre Frequency (Hz)

STL curve oftest wall

STC60STC55

STC50

STC45

85

80

75

70

65

60

55

50

45

40

35

30

25

20

100 125 160 200 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000

Soun

d Tr

ansm

issi

on L

oss.

STL

(dB)

Fig. 3.1 “Best Fit” of partition wall test result to standardised curves (STC60 standardised curve is the highest curve fitting the results)

Page 7: Hebel Supercrete AWS Design Guide

AWS 20097

Table 4.1 Systems Index for Hebel Supercrete AWS Walls

3.2 NZ Building Code Requirements Clause G6 of the NZBC requires that common walls between different occupancies must have an STC value of 55 or more, and that the IIC between floors must be at least 55. The NZBC allows the site performance of a wall when tested to have a STC a maximum of 5 decibels below the laboratory test value.

3.3 Acoustic AnalysisIncreasing the STC rating of a particular wall system is possible by varying types of lining on one or both sides of the panel, varying cavity widths, and varying supplementary

4.0 Selection of AWS TypeSelection of the appropriate wall system depends primarily on the type of building construction and acoustic performance required. It can also depend on the finished wall thickness, fire rating, construction time and cost.

The four types of Acoustic Intertenancy Wall Systems are summarized in Table 4.1 and specific details are shown in the following diagrams for each system.

Wall ThicknessWall System Type

TYPE 1

TYPE 2

TYPE 3

TYPE 4

STC

63 to 67

61 to 64

56

64

305 to 331

171 to 193

245

200

Fire Rating*

90/90/90

-/180/180* to

-/240/240

-/120/120*

-/120/120* to

-/240/240

Applications

• Low rise multi-residential.

• Used where full height intertenancy wall is required to isolate each side from fire transfer, as well as for acoustic performance.

• Load bearing, bracing applications

• Used primarily for non load bearing walls between floors.

• Used where maximum floor space is to be achieved and where services on one side of the wall are to be concealed.

• Used primarily for non load bearing walls between floors.

• Lightweight partition walls between units where services on both sides of the wall are to be concealed.

• Used primarily for non load bearing walls between floors.

• Lightweight partition walls with ultra high acoustic performance. Used where a solid wall is required on both sides.

*Depends on wall height – refer Table 5.1

Thermal Resistivity R

5.5

3.0

5.2

2.8

insulation. However, acoustic analysis is not straight forward as different densities of material will absorb different frequencies of sound, and combinations of different materials will act differently again. The STC for each layer of a wall cannot therefore be added together, to give a total STC for the wall, as the STC is a value based on all frequencies in the test range. It is recommended that you seek advice from an acoustic consultant where the acoustic performance of the wall must achieve a set STC. Remember that the site performance of the wall may be less than the laboratory test or opinion as it will be affected by the presence of flanking paths, quality of installation, detailing of wall junctions and services, room sizes and shapes, and floor construction.

Note that a bare 75 mm Hebel Supercrete Panel will have an STC rating of 37.

Page 8: Hebel Supercrete AWS Design Guide

AWS 2009 8

Details to be read in conjuction with the current Hebel Supercrete Acoustic Wall Systems Design Guide, AWS 2009

Detail 4.1.1 Type 1 Wall System – Full height Hebel Supercrete Panel intertenancy wall

See details for base options

No penetrations permitted through the Hebel Supercrete Panel

Hebel Adhesive at edge joints

Services must run through wall frame and must not be fixed to the Hebel Supercrete Panel

Services may penetrate decorative wall without fire caulking

Plasterboard lining fixed with 25mm needle point screws. Use Gib Aqualine or similar in wet areas

Timber or steel framing both sides

Insulation to project specification

Type 1 Wall System

* Lining 1 – Single layer of Plasterboard screw fixed/glued to framing

* 100mm nominal timber framing or steel framing equivalent

* 90mm R 2.0 minimum fibreglass insulation

* 10 to 20mm gap

* 75mm Hebel Supercrete panel, non loadbearing, steel reinforced AAC panel

* 10 to 20mm gap

* 90mm R 2.0 minimum fibreglass insulation

* 100mm nominal timber framing or steel framing equivalent

* Lining 2 – Single layer of Plasterboard screw fixed/glued to framing

STCWall Width

mmFire Ratingminimum

System Variations

Lining 1 Lining 2

63 All305 to 331

Depending on timber size & lining type

All

90/90/90

10mm Plasterboard 10mm Plasterboard

64 13mm Plasterboard 13mm Plasterboard

67 13mm Gib Noiseline* 13mm Gib Noiseline*

63 10mm Gib Aqualine* 10mm Gib Aqualine*

* or equivalent products of similar density

Page 9: Hebel Supercrete AWS Design Guide

AWS 20099

Details to be read in conjuction with the current Hebel Supercrete Acoustic Wall Systems Design Guide, AWS 2009

Detail 4.1.2 Vertical cross section of Type 1 Wall

Refer to horizontal joint detail Section 12

3000mm max. from bracket to bracket

Hebel Supercrete Soundfloor AAC floor sheeting on joists

Floor joists may be perpendicular or parallel to wall

600mm max. from bracket to joint in panel

Timber or steel framing as per project specifications

Additional noggings and clips required in offset floor level applications

75mm Hebel Supercrete Panel

Wall brackets each side of panel

Wall bracket

Base detail. Refer to alternative methods in Section 12

10-20 mm gap on each side

Concrete slab

Bracket fixed to framing and panel (refer to fixing detail) Bradford or similar insulation

as per project specification

Bradford or similar insulation as per project specification

Bradford or similar insulation as per project specification

Bradford or similar insulation as per project specification

Refer to Detail Section 12

3000mm max. panel height

3000mm max. panel height

3000mm max. panel height

Mineral fibre or other fire-resisting material as per project specifications if panel does not extend to underside of roofing

Page 10: Hebel Supercrete AWS Design Guide

AWS 2009 10

Details to be read in conjuction with the current Hebel Supercrete Acoustic Wall Systems Design Guide, AWS 2009

Detail 4.2 Type 2 Wall System – 75mm Hebel Supercrete Panel with separated stud

Fill gap with fire and acoustic rated sealant to manufacturer's recommendations

Fill gap with fire and acoustic rated sealant to manufacturer's recommendations

Fill 10mm gap with fire and acoustic rated sealant to manufacturer's recommendations

Fill 10mm gap with fire and acoustic rated sealant to manufacturer's recommendations

22mm IBS rod

Rondo deflection head tracks fixed to soffit at 600mm max. centres to project specifications

Plasterboard lining fixed with 50mm bugle head coarse thread screws

Mortar as required between slab and panel

Rondo base angle fixed to slab at 600mm max. centres to project specifications

Concrete soffit

Concrete slab

75mm Hebel Supercrete Panel fixed edge to edge with Adhesive

Plasterboard lining fixed with 25mm needle point screws

Fix Hebel Supercrete Panel to base angle with 1 x 14-10 x 65mm hex head screw 50mm from each corner

Rondo steel studs and noggings to manufacturer's specifications

Rondo base track fixed to floor to manufacturer's specifications

Bradford or similar insulation to project specifications

22mm IBS rod

Concrete soffit

Concrete slab

Insulation as per system requirements

Rondo steel stud framing systemPlasterboard

as per system requirements

Plasterboard as per system requirements

75mm Hebel Supercrete Panel

Fire and acoustic rated sealant

Fire and acoustic rated sealant

10mm fire and acoustic rated sealant

10mm fire and acoustic rated sealant

Rondo base angle fixed to slab

Rondo track fixed to slabMortar as required

50mm bugle head coarse thread screw

25mm needle point screws

14-10 x 65mm hex head screw

J-track or deflection head fixed to soffit

Detail 4.2. Type 2 – Vertical cross-section

Page 11: Hebel Supercrete AWS Design Guide

AWS 200911

Type 2 Wall System

* Lining 1 – Single layer of Plasterboard screw fixed to Hebel Supercrete Panel

* 75 mm Hebel Supercrete Panel (non loadbearing, steel reinforced AAC panel)

* 12 mm minimum gap

* Rondo or similar 64 mm steel studs at 600mm maximum horizontal centres. Fitted in deflection head track at soffit and base track at floor.* 75 mm fibreglass insulation infill

* Lining 2 – Single layer of Plasterboard screw fixed to steel studs

STCWall Width

mmFire Rating(minimum)

System Variations

Lining 1 Lining 2

61 171 -/180/180 10mm Plasterboard 10mm Plasterboard

61 177 -/180/180 13mm Plasterboard 13mm Plasterboard

61 181 -/240/180 10mm Gib Aqualine* 10mm Gib Aqualine*

61 181 -/240/180 10mm Gib Aqualine* 10mm Gib Aqualine*

63 184 -/240/180 10mm Gib Aqualine* 10mm Gib Fyreline*

64 193 -/240/180 16mm Gib Fyreline* 16mm Gib Fyreline*

Note: Fire ratings may be higher depending on wall height. Refer Table 5.1

* Or equivalent products of similar density

Fig. 4.1 Typical Type 2 wall installation

Page 12: Hebel Supercrete AWS Design Guide

AWS 2009 12

Details to be read in conjuction with the current Hebel Supercrete Acoustic Wall Systems Design Guide, AWS 2009

Detail 4.3 Type 3 Wall System – 75mm Hebel Supercrete Panel with double separated stud

Fill gap with fire and acoustic rated sealant to manufacturer's recommendations

Fill gap with fire and acoustic rated sealant to manufacturer's recommendations

Fill 10mm gap with fire and acoustic rated sealant to manufacturer's recommendations

Fill 10mm gap with fire and acoustic rated sealant to manufacturer's recommendations

22mm IBS rod

Rondo deflection head tracks fixed to soffit at 600mm max. centres to project specifications

Plasterboard lining fixed with 50mm bugle head coarse thread screws

Mortar as required between slab and panel

Rondo base angle fixed to slab at 600mm max. centres to project specifications

Concrete soffit

Concrete slab

75mm Hebel Supercrete Panel fixed edge to edge with Adhesive

Bradford insulation to project specifications

Plasterboard lining fixed with 25mm Type 'S' needle point screws

Fix Hebel Supercrete Panel to base angle with 1 x 14-10 x 65mm hex head screw 50mm from each corner of each panel

Rondo steel studs and noggings to manufacturer's specifications

Rondo steel studs and noggings to manufacturer's specifications

Rondo base track fixed to floor at 600mm max. centres to project specifications

Rondo base track fixed to floor to manufacturer's specifications

Fig. 4.2 Typical Type 3 wall installation

Page 13: Hebel Supercrete AWS Design Guide

AWS 200913

22mm IBS rod

Concrete soffit

Concrete slab

Insulation as per system requirements

Rondo steel stud framing system

Plasterboard as per system requirements

Fire and acoustic rated sealant

10mm fire and acoustic rated sealant

Rondo base angle fixed to slab

Rondo track fixed to slab

Rondo track fixed to slab

25mm needle point screws

14-10 x 65mm hex head screw

J-track or deflection head fixed to soffit

75mm Hebel Supercrete Panel

Mortar as required

Insulation as per system requirements

Rondo steel stud framing system

Plasterboard as per system requirements

Fire and acoustic rated sealant

10mm fire and acoustic rated sealant

25mm needle point screws

Detail 4.3 Type 3 – Vertical cross-section

Wall System Type 3 * Lining 1 – Single layer of 10 mm Plasterboard screw fixed to steel studs

* Rondo or similar 64mm steel studs at 600 mm maximum horizontal centres.

Fitted in deflection head track at soffit and base track at floor.

* 12 mm minimum gap

* 75 mm Hebel Supercrete Panel (non loadbearing, steel reinforced AAC panel)

*12 mm minimum gap

* Rondo or similar 64 mm steel studs at 600 mm maximum horizontal centres.

* 50 mm fibreglass insulation infill

* Lining 2 – Single layer of 10mm Plasterboard screw fixed to steel studs

STC 56

Wall width 245mm

Fire rating Minimum

-/120/120

Note: Fire ratings may be higher depending on wall height. Refer Table 5.1

Page 14: Hebel Supercrete AWS Design Guide

AWS 2009 14

Details to be read in conjuction with the current Hebel Supercrete Acoustic Wall Systems Design Guide, AWS 2009

Detail 4.4 Type 4 Wall System – Double 75mm Hebel Supercrete Panel

30mm cavity

Concrete soffit

Concrete slab

Fill gap with fire and acoustic rated sealant to manufacturer's recommendations Fill gap with fire and acoustic

rated sealant to manufacturer's recommendations

Fill 10mm gap with fire and acoustic rated sealant to manufacturer's recommendations

22mm IBS rod

Plasterboard lining fixed with 50mm bugle head coarse thread screws

Plasterboard lining fixed with 50mm bugle head coarse thread screws

Fill 10mm gap with fire and acoustic rated sealant to manufacturer's recommendations

Bradford insulation to project specifications

Fix Hebel Supercrete Panel to base angle with 1 x 14-10 x 65mm hex head screw 50mm from each corner. (Use 14-10 x 100mm MP bugle head screw when fixing from Hebel side)

Rondo deflection head tracks fixed to soffit at 600mm max. centres to project specifications

Rondo deflection head tracks fixed to soffit at 600mm max. centres to project specifications75mm Hebel Supercrete Panel

fixed edge to edge with Adhesive

Mortar as required between slab and panel

Rondo base angle fixed to slab at 600mm max. centres to project specifications

Detail 4.1 Type 4 – Vertical cross-section

22mm IBS rod

Concrete soffit

Concrete slab

J-track or deflection head fixed to soffit

Fire and acoustic rated sealant

Fire and acoustic rated sealant

10mm fire and acoustic rated sealant

10mm fire and acoustic rated sealant

14-10 x 100mm MP bugle head screw

14-10 x 65mm hex head screw

Rondo base angle fixed to slab

50mm bugle head coarse thread screw

Nº10 x 50mm bugle head coarse thread screw

Plasterboard as per system requirements

Plasterboard as per system requirements

Mortar as required

75mm Hebel Supercrete Panel

75mm Hebel Supercrete Panel

Insulation as per system requirements

Wall System Type 4

STC 64

Wall width 200mm

Fire rating Minimum

-/120/120

* Lining 1 – Single layer of 10mm Plasterboard screw fixed to Hebel Supercrete panel

* 75mm Hebel Supercrete Panel (non loadbearing, steel reinforced AAC panel)

* 30mm minimum cavity between panels

* 50mm fibreglass insulation

* 75mm Hebel Supercrete Panel (non loadbearing, steel reinforced AAC panel)

* Lining 2 – Single layer of 10mm Plasterboard screw fixed to Hebel Supercrete Panel

Note: Fire ratings may be higher depending on wall height. Refer Table 5.1

Page 15: Hebel Supercrete AWS Design Guide

AWS 200915

5.0 Fire Resistance Performance5.1 Fire Resistance Rating (FRR) of AWS WallsFire ratings for each wall type, dependant on height, are shown in Table 5.1. These are derived from CSIRO Fire Opinions FCO 2073 and FCO 2327 for Types 2, 3 and 4 and WFRA-45771.3 from Warrington Fire Research (Aust) Pty Ltd for Type 1 and are available from CFG Concrete Ltd if required.

Most multi occupant structures are only required by the NZ Building Code to have a 30/30/30 minute fire rating for structural adequacy, integrity and insulation respectively. 75mm Hebel Supercrete Panel on its own has a fire rating of 180/180/180 minutes, so it is the detailing of fastenings that hold the panels in place and their protection from any outer linings, that will determine the fire rating of the acoustic wall.

Note that the overall fire rating of a wall can be affected by any penetrations through the wall and the methods adopted to protect these penetrations. For example, a fire collar around a service pipe with a -/120/120 minute fire rating will restrict the overall fire rating of the wall to -/120/120 minutes, even if the wall panels have a fire rating of -240/240/240 minutes. Penetrations can be protected by fire rated sealants, intumescent fire collars, or fire rated mortars.

5.2 System VariationsCertain variations to the Hebel Supercrete AWS walls will not affect the fire-resistance levels listed in Table 5.1. However these variations need to be approved by the project fire consultant or project certifier. The possible variations to the systems include:

1) Changing the type or density of insulation;

2) The incorporation of gaps between the steel stud (51mm, 64mm, 76mm or 92mm deep steel studs) and the Hebel Supercrete Panel of up to 100mm maximum (Wall Types 2 and 3)

3) Cavity widths of up to 250mm between panels in double panel walls (Wall Type 4).

Table 5.1 Fire Resistance Rating of Hebel Supercrete AWS walls

WallSystem Type

Maximum Wall Height (mm)

Fire Resistance Rating (mins)

-/60/60 -/90/90 90/90/90* -/120/120 -/180/180 -/240/240

Type 1 12000 12000 12000 N/A N/A N/A

Type 2 3900 3900 N/A 3900 3000 N/A

Type 3 3900 3900 N/A 3900 3000 N/A

Type 4 3900 3900 N/A 3900 3600 3000

Note: The values in Table 5.1 should be read in conjunction with CSIRO Fire Opinions FCO-2073 and FCO-2327, and WFRA-45771.3 from Warrington Fire Research (Aust) Pty Ltd.

*Wall Type 1 is the only structural load bearing wall system needing a structural adequacy value.

Fig. 5.1 Hebel Supercrete Panels stay intact after the remainder of the building has burnt.

Page 16: Hebel Supercrete AWS Design Guide

AWS 2009 16

6.1 Structural PerformanceHebel Supercrete AWS Type 1 can either be loadbearing or non loadbearing. The Hebel Supercrete panel in the wall is non load bearing apart from self weight. All other Hebel Supercrete AWS wall types are non-loadbearing walls used in internal applications. The walls are designed to resist a maximum permissible uniformly distributed load (UDL) of 0.25kPa (this equates to an internal wind speed of 20m/s with a pressure coefficient of 1), and a deflection limit of H/240 (Height ÷ 240) or 20mm maximum.

6.2 High Lateral LoadingFor UDL loads greater than 0.25kPa the standard Hebel Supercrete Panel and associated components may not have sufficient capacity. These panels and components will have to be designed to ensure structural adequacy. CFG Concrete Ltd can confirm the adequacy of the panel and the project engineer can confirm the adequacy of the components such as deflection head, base angle, studs, furring channels and fixings.

6.3 Wall HeightsThe overall wall height limit for Type 1 walls is 12.0 metres using standard Hebel Supercrete Panels up to 3.0m high. Panels greater than 3200mm in height should have the deflection head track replaced with two 50 x 50 x 1.2mm galvanised steel angles (see detail 12.1.9) and a 50 x 50 x 1.2mm galvanised steel angle at the base.

6.4 Cutting of Hebel Supercrete PanelFor the load parameters outlined above (UDL ≤ 0.25kPa), the standard Hebel Supercrete Panel can be reduced to a minimum width of 270mm without compromising reinforcement.. For UDL loads greater than 0.25kPa, custom Hebel Supercrete Panel will have to be designed to ensure structural adequacy when cut.

6.0 Structural Performance6.5 Steel Stud FrameThe steel framing presented in this Design Guide for various wall systems has not been approved for the design parameters in this Design Guide. It is the designer’s responsibility to determine an appropriate steel framing system. Several items the designer must allow for are; lateral loadings, wall height, deflection limits, offset distance (gap) from the panel, building movement and control joint locations.

As a minimum the wall will have a deflection limit of H/240. As a guide, CFG Concrete Ltd recommends providing a minimum gap distance of Height/240 + installation tolerance. For example, H = 2400mm and installation tolerance = 2mm, then minimum gap = 2400/240+2 = 12mm. This is to ensure that the two leaves of the cavity wall do not touch during service loading.

Table 6.1 outlines the recommended minimum gap to suit a range of wall heights for the H/240 deflection limit.

6.6 Custom Hebel Supercrete PanelFor Wall Types 2, 3 & 4, for heights exceeding 3000mm or design parameters outside the scope of this guide, the panels will be custom Hebel Supercrete Panel. These panels are designed to satisfy the project’s design parameters, such as internal lateral (wind) pressure and on-site cutting requirements.

Note that actual lateral design loads may limit the height of wall possible.

Wall*Height(mm)

H/240

(mm)

Minimum Gap

(mm)

2400 10 12

2550 11 13

2700 12 14

2850 12 14

3000 13 15

3200 14 16

3550 15 17

3900 17 19

Table 6.1 Recommended minimum gap between the Stud Frame and the Hebel Supercrete Panel Wall.

* or vertical distance between fastenings to Hebel Supercrete panel.

Fig. 6.1 Hebel Supercrete panel being cut with portable saw with diamond blade

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6.7 FasteningsAll fastenings for deflection head channels, base angles, wall brackets and panels must be checked to ensure that the shear load applied by earthquake loads from the wall mass are within the capacity of the fastening. For Type 1 walls, where the Hebel Supercrete panels are exposed to external wind loads during construction, CFG Concrete Ltd recommends that the fastenings for securing angles and tracks to floor slabs be capable of withstanding a shear load of 0.75kN minimum. Depending on the structure size, site conditions and location, the designer may have to specifically design these for wind loads during construction. Minimum fastenings for Type 1 walls are shown in Table 6.2.

Location Fixing Type Number of Fixings and Spacing

Bottom angle/track to structure M8 bolt + 25 x 3mm load sharing washer 600mm max. centres

Bottom angle to Hebel Supercrete Panel

12-11 x 90mm hex head screws 2 fixings per panel, 50mm min. from panel edge.

Track back-to-back 10-16 x 16mm wafer head screws 600mm max. centres

Aluminium bracket to timber frame 12-11 x 25mm hex head screws 2 fixing per bracket

Aluminium bracket to steel frame 10-16 x 16mm hex head self-drilling screws 2 fixing per bracket

Aluminium bracket to Panels 12-11 x 50mm hex head screws or 12-8 x 60mm button head screws

2 fixings per bracket

Table 6.2 Fastenings for Wall Type 1

6.8 Lightweight Support FramingTypically Type 2, 3 & 4 walls are secured to concrete slabs and soffits. For walls that are secured at the head connection to lightweight support framing, such as structural steel roof framing, allowance must be made for vertical upward and downward movement. The magnitude of this movement could result in the standard head connections detailed in this Design Guide being inadequate. Contact your CFG Concrete Ltd representative to discuss the required head connection configuration.

7.0 Design & Installation ConsiderationsControl Joints

Control joints must be provided at a maximum of 6m spacing. Recommended control joint widths should be 10mm minimum between Hebel Supercrete Panel and another building component. Control joints must also be provided to coincide with any control joint in the main structure. The deflection head and base angle must be discontinuous at a structural control joint. These joints must use acoustic and fire rated sealants. Refer to Section 13.3 for control joint details.

Wet Area Wall Construction

Wet area wall construction requires a system that enables services to be installed in a cavity. Where back-to-back wet areas are to be installed, a Type 1 or Type 3 wall, which incorporate a cavity on both sides of the wall, is required.

Penetrations

Hebel Supercrete AWS walls can accommodate 300 x 300mm penetrations at 1200mm horizontal centres, without a reduction in structural performance. The edge of the penetration shall be 15mm maximum from the service passing through the wall. Contact your fire and acoustic consultants for detailing of penetrations to ensure the nominated fire and/or acoustic performance is achieved.

Wall Chasing

Panels should not be chased for services.

Acoustic & Fire Integrity

Penetrations in walls for electrical fittings, telecommunications, large ductwork, or plumbing systems can be a substantial source of sound leakage, which can affect the acoustic and fire performance of the wall.

When electrical, telecommunication or plumbing services are required, the contractor shall install these services neatly and, when passing through the wall, shall provide a close fitting hole, sealed with an approved fire and acoustic rated sealant. Detail of stopping material to be provided by appropriate consultant and installed in accordance with the manufacturer’s recommendations.

To prevent water noise from degrading acoustic performance of the wall system, water-bearing pipes should be acoustically wrapped and resiliently fastened.

CFG Concrete Ltd recommends the use of fire rated switch boxes and collars (such as those manufactured by CLIPSAL or HPM) as these assist in maintaining the acoustic integrity of wall systems. When installing these devices please consult with the manufacturer for design and installation recommendations.

Electrical switches must not be installed back to back as this could be a source of sound leakage. Refer figure 7.1 for switch box layout guidance.

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600mm min.

Fig 7.1 Switch Box Layout

PANELTYPE

LENGTH (mm)

PANEL DIMENSIoNS WEIGHT①

(kg/m2)WIDTH (mm)

300 600

Standard 1200 ✓ 49

2400 ✓ ✓ 49

2550 ✓ 49

2700 ✓ ✓ 49

2850 ✓ 49

3000 ✓ ✓ 49

Custom 3000 max ✓ 49

3200 ✓ 49

Up to 3900 ✓ 53②

Note:① Average panel weight worked out at 30% moisture content.② Double reinforcement

8.0 System ComponentsCFG Concrete Ltd recommends that the following components or equivalent be used.

Note: ① Optional if in Detail 12.14 head track connection is specified.② Use as required.

Hebel Supercrete Panel

The primary component of Hebel Supercrete AWS walls is the 75mm thick Hebel Supercrete Panel. The panel is manufactured specifically for each job in a range of standard and custom sizes as indicated in Table 8.2.

The standard panel is produced as a stock item, unlike the custom panel, which has to be manufactured and availability is subject to production lead times. Standard panels are manufactured with flat butt joints.

Deflection Head Track

For positioning and restraining the top of the panels the following deflection head tracks and angles are recommended for use in the AWS walls types 2, 3 and 4:

• Rondo Nº498 galvanised deflection head track 76 x 50 x 0.75mm base metal thickness (BMT);

• Rondo J-Track Deflection Head 76 x 100 x 50 x 0.75mm BMT; or

• Galvanised steel angle 50 x 50 x 1.2mm BMT.

For TP Head use:

• Slotted galvanised steel angle 75 x 50 x 1.2mm BMT.

Table 3.1 Typical Hebel Supercrete AWS Wall Components

Table 8.2 Standard and Custom 75mm Hebel Supercrete Panel Sizes

75mm

600mm

T&G ProfileStandard (Nil) Profile

75mm

600mm

Fig 8.1 Hebel Supercrete Panel Standard and T&G cross-sections

WALL CoMPoNENTS WALL SYSTEM TYPE

Type 1 Type 2 Type 3 Type 4

75mm Hebel Supercrete Panel ✓ ✓ ✓ ✓

Head track ✓ ✓ ✓

Base angle ✓ ✓ ✓

Steel stud framing ✓ ✓ ✓

Timber stud framing ✓

Wall brackets ✓

Plasterboard ✓ ✓ ✓ ✓

Promaseal® IBS™ rod ✓① ✓① ✓①

Adhesive ✓ ✓ ✓ ✓

Mortar ✓ ✓ ✓ ✓

CSR Bradford insulation ✓ ✓ ✓ ✓

Fasteners/fixings ✓ ✓ ✓ ✓

Acoustic/fire sealants ✓ ✓ ✓ ✓

Corrosion protection paint ✓② ✓② ✓② ✓②

50 or35mm

76mm

Door Frames

Door frames can either be built-in as the wall is being constructed or retrofitted after the Hebel Supercrete Panel has been installed.

A typical door frame details have been included in Section 12.6. For further information and installation requirements, please contact your chosen door frame manufacturer.

Fasteners

The correct sized fasteners for the construction of the wall system must always be used. When fitting large or heavy

fixtures, guidance on the correct fasteners can be found in the Hebel Supercrete Fixing and Fastening Guide and/or fastener manufacturer’s recommendations.

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Base Angle/Channel

For positioning and restraining the bottom of the panels, the following base angles are recommended for use:

• Slotted galvanised steel angle 50 x 50 x 0.8mm BMT;

• Slotted galvanised steel angle 50 x 50 x 1.2mm BMT; or

• Punched base angle;

• Galvanized deflection head track Rondo No 498 76 x 50 x 0.75mm BMT, or Rondo No 402 76 x 35 x 0.75 BMT.

All angles with BMT greater than 0.8mm will have to be slotted.

Wall Brackets

Wall brackets for Wall Type 1 are proprietary components nominally 75 x 40 x 1.6mm x 50mm wide. These can be aluminium, galvanized steel or zincalume.

Mortar

Mortar is used to provide a level base for panel installation as well as providing acoustic and fire protection at the base of the panels.

Mortar (supplied in 20kg bags) is used only as a mortar base, typically 10mm thick. Do not use for joints between panels.

Adhesive

Adhesive (supplied in 20kg bag) is used for bonding the panels together at vertical and horizontal joints. Joints should be 2-3mm thick.

PromaSeal® IBS™ Rod

Promaseal IBS Rod (22mmØ) is a fire rated seal appropriate for 15mm maximum gaps and used on wall types 2, 3 & 4. It is positioned inside the deflection head track and compressed 7mm. Promaseal® IBS™ Rod is available from PBS Distributors and Contracting Ltd, Auckland, or PBS South Island Ltd.

Corrosion Protection Coating

Reinforcement exposed when panels are cut shall be coated with a liberal application of Fentak Dipcoat or similar.

Stud Framework

Zinc coated steel studs, noggings, head and base tracks are used to create separated stud framework, which in conjunction with the Hebel Supercrete Panel, provides a cavity wall assembly for wall types 1, 2 or 3.

There are number of different steel stud framework component manufacturers. All steel stud framework components are to be designed in accordance with manufacturer’s specifications, and AS/NZS 4600.

Wall Type 1 may also be constructed using timber framing complying with NZS 3604.

Insulation Hebel Supercrete AWS walls incorporate supplementary insulation materials. Tables 8.1 present basic information on glasswool insulation materials.

Hebel Supercrete AWS wall systems that use glasswool insulation generally have a better acoustic performance than systems using Polyester insulation.

CFG Concrete Ltd recommends the use of CSR Bradford Glasswool insulation. Additional information regarding Bradford insulation is available from www.bradfordinsulation.com.au

PlasterboardHebel Supercrete AWS walls incorporate Plasterboard on both sides. The type, thickness and densities of plasterboard will be as per the specified wall requirements. Additional information is available from plasterboard manufacturers/suppliers.

Fasteners & FixingsMost screw fixings are timber type, which is sufficient for penetrating the metal thicknesses outlined in this Design Guide. Connections that have larger metal thicknesses may require a metal type screw and will need to be designed and approved by the project engineer.

Fixings for Deflection Head Track and Base Angle to Concrete

The fixing to secure the tracks to the concrete slab and soffits shall be capable of withstanding a shear load of 0.75kN. For high wind or earthquake loads the designer shall

50mm

75mm

40mm

Wall bracket

Table 8.1. CSR Bradford Glasswool insulation

Glasswool Thickness Mass g/m2

50mm 540

75mm 810

90mm 940

105mm 683

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determine if mechanical fasteners are required. The following minimum fixings shall be provided:

• Drive pins and concrete nails (check size and suitability for fire rated situations with the manufacturer).

• 6mm diameter mechanical fasteners.

• For Wall Type 1, use M8 Dynabolts or similar with 25mm x 3mm load spreading washers.

Hebel Supercrete Panel to Base Angle Fixings

• Use 14-10 x 65mm hex head screw or equivalent, when fixing through the track into the panel. (See Figure 8.1). Angles with BMT greater than 0.8mm will have to be slotted.

• Use 14-10 x 90mm MP Bugle Head screw or equivalent, when fixing through the panel and into the track. For angles with BMT greater than 0.8mm, the screw will require the appropriate tip.

Back to Back Track Fixings

• For joining steel channels for panel joints in Wall Type 1 (option 2 Detail use 10-16 x 16 mm self drilling wafer head screws. These must be used with the tracks sitting in place on the lower panel so the screw enters the lower panel.

Wall Brackets for Wall Type 1

• Use 12-11 x 25mm hexagon head screws into timber frames.

Fig 8.1 14-10 x 65mm hex head

• Use 10 x 16 x 16mm self drilling hexagon head screws into steel frames.

• Use 12-11 x 50mm hexagon head screws to fasten brackets to Hebel Supercrete Panel.

Plasterboard to Hebel Supercrete Panel Fixings

• 50mm bugle head coarse thread screw or equivalent. (See figure 8.3).

Door Frames to Hebel Supercrete Panel Fixings

• 50mm coarse thread screw or equivalent. Check screw requirements with door manufacturer’s specifications.

Screws for panel returns

• Use 14-10 x 150mm (100mm thread) hex head screw or equivalent.

Fire & Acoustic Sealant

To attain the specified FRR and/or STC requirements, all perimeter gaps and penetrations must be carefully and completely filled with an appropriate flexible polyurethane sealant installed to manufacturer’s specifications.

Fig 8.3 50mm bugle head coarse thread screw

Fig 8.2 12-11 x 50mm hex head screw

9.0 Installation of AWS WallsSetting Out and Positioning of Walls

Before commencing any installation work, clean and tidy up the work area. Mark out the location of the walls and door nibs, etc.

Deflection Head Track and Base Angle Installation

When the wall locations have been set out fix the deflection head tracks and base angles to the concrete support structures. This is done using suitable fixings (see Section 8) at 600mm maximum centres and maximum 100mm from ends. At changes in wall directions, ensure deflection head track is mitred with no gaps at the corners. Seal all butt joints with polyurethane sealant. Use a laser or plumb line to ensure vertical alignment.

Gaps between the deflection head track and irregular soffit surfaces should be sealed with a 5mm minimum diameter bead of sealant as per project specifications.

Promaseal® IBS™ Rod Installation

Promaseal IBS Rod or equivalent is positioned inside the deflection head track. Tape or contact adhesive may be used to temporary secure the rod in place prior to installation of the panel. Select the appropriate diameter rod to suit the deflection gap at the top of the wall. For a 15mm gap adopt a 22mm diameter Promaseal IBS Rod.

The rod should be continuous through connections and the rod shall be spliced by overlapping a minimum of 200mm.

Mortar Installation

Mortar is placed after the base angle is installed, it should only be run out a maximum of 3 panels (1800mm) ahead of panel installation. The mortar bed fills the gap at the base as the IBS rod is compressed by the panels. Generally, the mortar is 10mm thick and shall extend the full width of the panel. Care must be taken not to drag mortar to the angle upstand, causing panel misalignment.

Mixing of the mortar should be done in accordance with the instructions on the bag.

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Hebel Supercrete Panel Installation

The panels can be cut on-site using a circular saw equipped with diamond tipped cutting blade (for panel cutting limitations refer to Section 6.3). All the loose AAC particles should be brushed off the panel with a rough broom. Steel reinforcement that is exposed during cutting must be coated with a liberal application of corrosion protection coating (see Section 8). Any minor damage and chips to the panels must be repaired with Adhesive mixed with AAC dust or High Build Render.

As the panel is positioned into place the rod must be compressed the specified minimum distance. A 22mm diameter Promaseal IBS Rod shall be used in a 15mm gap and shall be compressed 7mm minimum. No fixings should be used to compress the rod. Use packers at the base to maintain the gap at the top. Ensure base gap is full of mortar.

Fix the panel to the base angle with a minimum of 2 screws (see Section 8), 50mm minimum from each end of the panel.

For subsequent panels, apply Adhesive to the vertical edge and install next panel. Repeat the installation process until the wall is complete.

For Wall Type 1, wall brackets should be fastened first to stud wall and then to each panel as it is placed. Wall brackets to the second stud wall are fastened after the second stud wall is framed.

Adhesive Application

Adhesive is applied to the panel with a 75mm Hebel notched trowel.

When the panels are pushed together the joints are to be 2-3mm thick. Sufficient pressure must be applied to the panels when gluing to ensure the adhesive is fully bedded across the joint. Scrape off any excess adhesive protruding from the joints and fill any gaps.

Adhesive is to be mixed to the proportions and consistency as per the instructions on the bag.

Stud Framework Installation

For Wall Type 1, timber or steel stud framework on one side of the Hebel Supercrete Panel is erected before the panel is placed. For all other wall types, wall framing is installed after the panels.

All steel stud framework is to be installed to the manufacturer’s specifications.

Installation of Insulation

Installation of insulation should be completed in accordance with manufacturer’s handling and installation guidelines. The

thickness of insulation provided should be such as to fully fill the face of the cavity. If there is any gap in the insulation, the acoustic performance of the system may be adversely affected.

Plasterboard

Plasterboard sheets must be cut to fit neatly and should not be forced into position. The plasterboard is to extend the full height of the wall with gaps at top and bottom for the specified sealant.

In Hebel Supercrete AWS walls, plasterboard is fixed directly to Hebel Supercrete Panel or stud framework.

■ Direct fix to Hebel Supercrete: Plasterboard is to be installed in accordance with the plasterboard manufacturers installation guidelines and secured in position with the appropriate screws (see Section 8.0).

■ Stud Side: Plasterboard is to be installed in accordance with the manufacturers recommendations for steel frame or timber frames wall systems.

Installation of Sealants

All movement joints and other gaps should be sealed off and finished neatly with fire and acoustic rated sealants. Installation of sealants must be carried out in accordance with the manufacturer’s specifications.

Installation of Penetrations, Electrical, Plumbing and Other Services

Installation of services and penetrations into Hebel Supercrete AWS walls should be carried out in an appropriate construction sequence. This will allow easy access to cavities, steel framed elements and panels, where services can be easily installed and neatly hidden.

CFG Concrete Ltd suggests installing the plumbing and cabling after the panels have been installed. The builder or project manager should confirm appropriate construction sequence for services and penetrations on a project-by-project basis.

Neat finishes for all penetrations is necessary to maintain the acoustic and fire integrity of the wall. For more information regarding installation of services and penetrations refer to Sections 7 & 12.7 of this Design Guide.

Installation of Fasteners & Fixings

All fixings and fasteners should be installed in accordance with the manufacturer’s specifications.

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Manual Handling

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

To minimise the possibility of manual handling injuries, CFG Concrete Ltd suggests the following:

■ Use mechanical aids, such as trolleys, forklifts, cranes and levers, or team lifting to move panels.

10.0 Panel Handling

Fig 10.4 Personal Protection Equipment used when handling/cutting panels.

■ Keep the work place clean to reduce the risk of slips, trips and falls, which can cause injury.

■ Plan the sequence of installation to minimise panel movements and avoid awkward lifts.

■ Train employees in good lifting techniques to minimise the risk of injury.

Health and Safety

Hebel Supercrete 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 Supercrete products.

Approved respirators (AS/NZS1715 and AS/NZ1716) and eye protection (AS1336) should be worn at all times when cutting. Refer to the Hebel Supercrete Material Safety Data Sheets.

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

Refer to the back page of this Design Guide for further information regarding health and safety.

Fig 10.1 Positioning a panel onto the trolley Fig 10.2 Tipping the trolley onto its wheels

Fig 10.3 Transporting a panel to the wall

Dust Mask

Safety Goggles

Gloves

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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 panel damage. The repair of damage sustained during lifting and moving is the responsibility of the lifter. Where damage is excessive, panels must be replaced.

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 Supercrete products must be stacked on edge and properly supported off the ground, on a level platform. Panel bundles can be stacked two high for ease of access on site. The project engineer should be consulted as to the adequacy of the structure to support the stacked bundles. Each bundle contains 10 panels. Where bundles are stacked two high, the supporting cleats must be vertically aligned, to ensure minimal bending of the lower panels. Refer to Figure 11.2.

Where panels are being used in multi storey applications, the capacity of the floor to support the concentrated load of panel pallets must be checked prior to lifting on to the floor.

If Hebel Supercrete Panel is stored outside, it 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.

11.0 Delivery & Storage

Plastic shrinkwrap cover

Metalstrapping

Support pallet

HandingGuidelines

Fig 11.1 Hebel Supercrete 75mm Panel Shipping Bundle

Fig 11.2 Stacking Bundles of Hebel Supercrete Panels

Temporary joists may be required on uneven ground

Panel LengthPanel

Thickness

PanelWidth

PanelWidth

Strapping

Fig 11.3 Panels awaiting shipping at Somersby factory

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12.0 AWS Construction Details12.1 Hebel Supercrete Panel Construction Details

Detail 12.1.6. Bracket Fixing

Detail 12.1.1. Wall Type 1 Base Connection – option 1 Detail 12.1.4. Wall Type 1 Horizontal Joint Fixing – option 1

Details to be read in conjuction with the current Hebel Supercrete Acoustic Wall Systems Design Guide, AWS 2009

Continuous steel channel (Rondo 76 x 32 x 0.75mm) fixed with masonry anchors at 600mm max. ctrs

Plasterboard to system specification

Insulation to system specification

Plasterboard to system specification

Insulation to system specification

Continuous steel angle fixed to slab with masonry anchors at 600mm max. ctrs

Hebel Supercrete Panel fixed to continuous steel angle with 14-10 x 95mm hex head screws at 600mm max. ctrs

NOTE: This frame to be constructed first

Plasterboard to system specification

Timber or steel framing as per project specifications

10-20mm gap

Insulation to system specification

Continuous Mortar

Damp proof course

Aluminium bracket fixed to frame with 2 x 2mm x 25mm gal nails or 2 x 12-11 x 50mm hex head screws for timber framing, or 2 x 10-16 x 16mm wafer head screws for steel framing

75mm Hebel Supercrete Panel

Continuous Mortar

Damp proof course

Timber or steel framing as per project specifications

10-20mm gap75mm Hebel Supercrete Panel

Timber or steel framing as per project specifications

10-20mm gap

75mm Hebel Supercrete Panel

Detail 12.1.2. Wall Type 1 Base Connection – option 2

Continuous steel channel (Rondo 76 x 32 x 0.75mm) fixed with masonry anchors at 600mm max. ctrs

Plasterboard to system specification

Insulation to system specification

Plasterboard to system specification

Insulation to system specification

Continuous steel angle fixed to slab with masonry anchors at 600mm max. ctrs

Hebel Supercrete Panel fixed to continuous steel angle with 14-10 x 95mm hex head screws at 600mm max. ctrs

NOTE: This frame to be constructed first

Plasterboard to system specification

Timber or steel framing as per project specifications

10-20mm gap

Insulation to system specification

Continuous Mortar

Damp proof course

Aluminium bracket fixed to frame with 2 x 2mm x 25mm gal nails or 2 x 12-11 x 50mm hex head screws for timber framing, or 2 x 10-16 x 16mm wafer head screws for steel framing

75mm Hebel Supercrete Panel

Continuous Mortar

Damp proof course

Timber or steel framing as per project specifications

10-20mm gap75mm Hebel Supercrete Panel

Timber or steel framing as per project specifications

10-20mm gap

75mm Hebel Supercrete Panel

Detail 12.1.3. Wall Type 1 Base Connection – option 3

Continuous steel channel (Rondo 76 x 32 x 0.75mm) fixed with masonry anchors at 600mm max. ctrs

Plasterboard to system specification

Insulation to system specification

Plasterboard to system specification

Insulation to system specification

Continuous steel angle fixed to slab with masonry anchors at 600mm max. ctrs

Hebel Supercrete Panel fixed to continuous steel angle with 14-10 x 95mm hex head screws at 600mm max. ctrs

NOTE: This frame to be constructed first

Plasterboard to system specification

Timber or steel framing as per project specifications

10-20mm gap

Insulation to system specification

Continuous Mortar

Damp proof course

Aluminium bracket fixed to frame with 2 x 2mm x 25mm gal nails or 2 x 12-11 x 50mm hex head screws for timber framing, or 2 x 10-16 x 16mm wafer head screws for steel framing

75mm Hebel Supercrete Panel

Continuous Mortar

Damp proof course

Timber or steel framing as per project specifications

10-20mm gap75mm Hebel Supercrete Panel

Timber or steel framing as per project specifications

10-20mm gap

75mm Hebel Supercrete Panel

Detail 12.1.5. Horizontal Joint Fixing – option 2

Continuous steel channel 76 x 32 x 0.75mm BMT OR76 x 50 x 0.75mm Deflection Track or J-track

Fixed back to back with 10-16 x 16mm wafer head screws at 600mm max. centres

16mm Gib Fyreline Plasterboard or similar fixed to Hebel Supercrete Panel with 10 x 50mm bugle head laminating screws at 400mm centres max.

150mm min.

150mm min.

Wall bracket shall be fixed to panel within a 100mm wide central region of the panel

Centreline of panel

600mm wide Hebel Supercrete Panel (one panel)

50mm 50mm

Bracket fixed to frame with 2 x 2mm x 25mm gal nails or 2 x 12-11 x 25mm hex head type 17 screws for timber framing, or 2 x 10-16 x 16mm wafer head screws for steel framing

Bracket fixed to Hebel Supercrete Panel with 2 x Nº12-11 x 50mm hex head screws, or 2 x Nº12-8 x 60mm button head screws

Backing rod and fire and acoustic rated sealant to project specifications

Fibre Cement packer or non-combustible equivalent

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Detail 12.1.12. Base Angle

Detail 12.1.7. Deflection Head – Top Track. Use where H ≤ 3200mm for Wall Types 2, 3 & 4

Detail 12.1.9. Top Track. H ≥ 3200mm for Wall Types 2, 3 & 4 Detail 12.1.10.Top Track. Use where H ≤ 3000mm for

3000mm for Wall Types 2, 3 & 4

75mm HebelSupercretePanel

22mm IBS rod Fix angle to soffit slab

Galvanised Steel Angle50 x 50 x 1.2mm

15mm max.

35mm

Detail 12.1.11. Sealing of gaps between Top Track and Slab Soffits for Wall Types 2, 3 & 4

18.2.6 Sealing _ New Illo

Deflection headfixed to soffit

Fire andacoustic rated sealant

Apply sealantafter installation of Deflection Head

Concretesoffit

Option 1

Deflection headfixed to soffit

Fire andacoustic rated sealant

Deflection Headbedded insealant duringinstallation

Concretesoffit

Option 2

75mmHebelSupercretePanel

Backing rod Fix angle to soffit slab

Acoustic and fire rated sealant

14-10 x 65mm hex head screw

15mm max.

30mm

Slotted steel angle 75 x 50 x 1.2mm

Detail 12.1.8. J-Track – Top Track. Use where H ≤ 3200mm for Wall Types 2, 3 & 4

75mm Hebel SupercretePanel

18.2.2 j Track

22mm IBS rod

J-track fixed to soffit

Concretesoffit

75mm 35mm

15mm max.

75mm Hebel Supercrete Panel

Rondo base angle fixed to slab

Mortar as required

Concrete slab

14-10 x 65mm hex head screw

18.2.6 Base angle

Rondo steel angle 50 x 50 x 0.8mm(H<3200) or Rondo steel angle 50 x 50 x 1.2mm (H>3200mm)

22mm IBS rodDeflection headfixed to soffit

Concrete soffit

15mm max.

50mm

75mm Hebel Supercrete Panel

18.2.1 Deflection Head

35mm

Details to be read in conjuction with the current Hebel Supercrete Acoustic Wall Systems Design Guide, AWS 2009

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Masonry/concrete wall or column

Fire and acoustic rated sealant

Fire and acoustic rated sealant

10mm min.

Non fire rated foam backing rod

75mm Hebel Supercrete Panel

Detail 12.1.14 Panel To Column Junction. Use where H ≤ 3100mm and/or panel width ≥ 300mm

Adhesive between panels

14-10 x 150mm hex head coarse thread screw at 900mm max. centres and 100mm max. from panel ends (3 per panel min.)

75mm Hebel Supercrete Panel

Detail 12.2.18 Splay Corner Junction 14-10 x 150mm hex head coarse thread screw at 900mm max. centres and100mm max. from panel end (3 per panel min.)

Adhesive between panels

75mm Hebel Supercrete Panel

Detail 12.1.17 Corner Junction

Fire and acoustic rated sealant

Masonry/concrete wall or column

Rondo 75 x 50 x 0.75 min. head fixed to project specifications

22mm IBS rod

15mm max.

75mm Hebel Supercrete Panel

Detail 12.1.16 Panel to Column High Wall Junction. Use where H ≥ 3100mm and/or panel width ≤ 300mm

Detail 12.1.13 Vertical Edge – Square Edge Panels

Detail 12.1.15 Vertical Edge – T&G Profile Panels

Adhesive between panels

18.2.6 Vertical Edge

75mm Hebel Supercrete Panel

18.2.7 Vertical Edge

Adhesivebetween panels

75mm Hebel Supercrete Panel

Details to be read in conjuction with the current Hebel Supercrete Acoustic Wall Systems Design Guide, AWS 2009

Page 27: Hebel Supercrete AWS Design Guide

AWS 200927

Timber or steel framing as per project specifications

Hebel Supercrete intertenancy wall

Optional insulation75mm Hebel Supercrete Panel external wall system as per project specification

Building wrap

IMPORTANT: Provide a control joint at junction of the external wall and the Hebel Supercrete intertenancy wallBradford insulation as

per project

Plasterboard to system specification 10-20mm gap

Bradford Fibertex 450 Rockwool wedged between studs. Use 75mm thickness for 70mm frame, or 2 x 50mm thicknesses for 90mm frame.

Plasterboard to project specifications

Bradford Fibertex 450 Rockwool to 300mm min. each side of intertenancy wall

Optional insulation

UNIT 2

UNIT 1

EXTERNAL

Wall Brackets

Mineral fibre or other fire-resisting material as per project specifications for fire and acoustic purposes (nominal density ≥ 60kg/m3)

Rondo 303 battens

Building wrap

Optional insulation

10-20mm gap

Optional insulation

Bradford Fibertex 450 Rockwool to 300mm min. each side of party wall

Bradford Fibertex 450 Rockwool to 300mm min. each side of intertenancy wall

UNIT 2

UNIT 1

EXTERNAL

Wall brackets

Plasterboard to system specification

Bradford or similar insulation as per project specifications

Plasterboard to system specification

75mm Hebel Supercrete Panel external wall as per project specification

75mm Hebel Supercrete Panel external wall as per project specification

75mm Hebel Supercrete Panel intertenancy wall

NOTE: Fixings not shown for clarity

IMPORTANT: Provide a control joint at junction of the external wall and Hebel Supercrete intertenancy wall

Mineral fibre or other fire-resisting material as per project specifications for fire and acoustic purposes (nominal density ≥ 60kg/m3)

Detail 12.2.1: External Wall Junction for Wall Type 1

Detail 12.2.2: External Wall Corner Junction for Wall Type 1

12.2 Junction DetailsDetails to be read in conjuction with the current Hebel Supercrete Acoustic Wall Systems Design Guide, AWS 2009

Page 28: Hebel Supercrete AWS Design Guide

AWS 2009 28

Details to be read in conjuction with the current Hebel Supercrete Acoustic Wall Systems Design Guide, AWS 2009

75mm Hebel Supercrete Panel

Insulation as per system requirements

Plasterboard as per system requirements

Plasterboard as per system requirements

10mm fire and acoustic rated sealant

10mm fire and acoustic rated sealant

Masonry or concrete wall or column

Steel stud as per system requirements

Non fire rated backing rod and fire rated sealant

75mm Hebel Supercrete Panel

Insulation as per system requirements

Fire and acoustic rated sealant

Steel stud as per system requirements

Rondo deflection head fixed to project specifications

Plasterboard as per system requirements

Plasterboard as per system requirements

Masonry or concrete wall or column

Detail 12.2.3 Corner Junction – Type 2 Wall14-10 x 150mm hex head coarse thread screw at 900mm max. centres and 100mm max. from panel ends (3 per panel min.)

75mm Hebel Supercrete Panel

Hebel between panels

Plasterboard as per system requirements

Fire and acoustic rated sealant

Detail 12.2.5 Walls to Column Junction – Type 2 Wall for H ≥ 3100mm

Detail 12.2.4 Wall to Column Junction – Type 2 Wall for H ≤ 3100mm

Detail 12.2.6 Type 2 Wall Junction

Hebel Supercrete AWS Wall System

Hebel Supercrete AWS or Corridor Intertenancy Wall System

Unit 1

Unit 2

10mm fire and acoustic rated sealant

Non fire rated foam backing rod

Corridor or Unit 3

Detail 12.2.7 Type 4 Wall to External Wall Junction

18.3.9 75 pp

Vertical damp proofcourse full height of wall

CIWS Hebel Supercrete Panel

Coating system toproject specifications

EXTERNALSIDE

6mm x 300mm longstainless steel dowels (3 per panel min.)

Backing rodand sealant to projectspecification A

150mm

Fire and acoustic rated sealant betweendamp proof courseand external panels

Non-fire rated backingrod, and fire andacoustic rated sealantto project specification

Type 4 Wall

Internal wall system toproject specifications

A

Detail 12.2.8 Type 4 Wall to External Wall Junction – Section AA on Detail 12.2.5

Non fire rated backingrod, and fire and acousticrated sealant to projectspecifications

Damp proofcourse to projectspecifications

Fire and acoustic ratedsealant between dampproof course and panel

Sealant to project specifications

Panel bedded inMortar

Hebel SupercretePanel

Coating systemto projectspecifications

Waterproofmembrane to projectspecifications

Cement renderto projectspecifications

Refer to project acousticconsultant for appropriateacoustic treatment of cavity area

Concrete slab

Structural concretenib to project specification

Hebel Supercrete Type 4AWS wall system

Panel bedded inMortar

Hebel Supercrete AWS Intertenancy Wall System

Hebel Supercrete Internal Wall System or other Partition Wall Systems

Hebel Supercrete Internal Wall System or other Partition Wall Systems

Unit 1

Unit 2

Detail 12.2.9 Type 2 Wall to Internal Wall Junction

Page 29: Hebel Supercrete AWS Design Guide

AWS 200929

Details to be read in conjuction with the current Hebel Supercrete Acoustic Wall Systems Design Guide, AWS 2009

12.3 Roof Details

75mm Hebel Supercrete Panel

Timber framing as per project specification

Blocking 45mm thick between trusses as required

Bradford or similar insulation as per project specifications

Bradford or similar insulation as per project specifications

Bradford or similar insulation as per project specifications

20-25mm gap

Mineral fibre or other fire-resisting material as per project specifications for fire and acoustic purposes (nominal density ≥ 60kg/m3)

Wall brackets each side of panel

Max.1200mmbetween top hats

Bradford or similar insulation as per project specification

Bradford or similar insulation as per project specification

Bradford or similar insulation or similar as per project specification

Blocking 45mm thick between trusses as required

75mm Hebel Supercrete Panel

Timber framing as per project specifications

20-25mm gap

Mineral fibre or other fire-resisting material as per project specifications for fire and acoustic purposes (nominal density ≥ 60kg/m3)

Wall brackets each side of panel

Wall brackets each side of panel

Detail 12.3.1 Roof Valley for Wall Type 1

Detail 12.3.2 Roof Parapet for Wall Type 1

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AWS 2009 30

Detail 12.4.1 Type 2 and 3 Walls Fire Rated C.J.

Detail 12.5.1 Shower Area Detail 12.5.2 Bath Area

Concrete slab

Continuously fillgap with requiredsealant

Continuously fillgap with requiredsealant

Approved flashingwhen required bybuildingregulations

Foam plastic rodused as essentialbond breaker

Masking tape

Flexible sealant

Insitu internalmembraneapplied toface of walllining and floor

Ceramic tiles

Vertical cornerangle flashing

1 or 2 layers ofmoisture resistantplasterboard asper systemrequirements

Foam plastic rodused as essentialbond breaker

Masking tape

Flexible sealant

Insitu internalmembraneapplied toface of walllining andfloor

Ceramic tiles

Vertical cornerangle flashing

1 or 2 layers ofmoisture resistantplasterboard asper systemrequirements

Mortar bed Mortar bed

Steel Studs andinsulation asper systemrequirements

75mm Hebel Supercrete Panel

Continuously fill gapwith required sealant

Continuously fill gapwith required sealant

Ceramic tiles

1 or 2 layers of moistureresistantplasterboard asper systemrequirements

Mortar bed

Steel Studs andinsulation asper systemrequirements

Flexible sealant

6mm

Bath

Supportbattenfixed toframing

Ceramic tiles

1 or 2 layers of moistureresistantplasterboard as per system requirements

Mortar bed

Flexible sealant

6mm

Bath

Supportbattenfixed toframing

Concrete Slab

75mm Hebel Supercrete Panel

Required system wall linings

12.4 Control Joint (C.J.) Details

Details to be read in conjuction with the current Hebel Supercrete Acoustic Wall Systems Design Guide, AWS 2009

12.5 Wet Area Wall DetailsDetails to be read in conjuction with the current Hebel Supercrete Acoustic Wall Systems Design Guide, AWS 2009

Fire and acoustic rated sealant

Fire and acoustic rated sealant

RONDO P35 Control Joint with set finish

Backing rod non fire rated 22mm dia.

Backing rod non fire rated 22mm dia.

Plasterboard as per system specification

Plasterboard as per system specification

75mm Hebel Supercrete Panel

NOTES: For double layer lining systems, the minimum depth of approved fire and acoustic rated sealant shall be 20mm.

Stud in normal position

Additional stud to form control joint

Tracks to be discontinuous at control joint

15mm max.

10mm

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AWS 200931

Detail 12.5.1 Door opening – Type 1

Rondo deflection head powerfixed to slab

14-10 x 150mm hex head coarse thread screws

Lintel ( Hebel Supercrete Panel)

Door opening

300mm min.Base angle powerfixed to slab

Lintel ( Hebel Supercrete Panel)

Rondo deflection head powerfixed to slab

Fully glue lintel panel to adjacent panels

Base angle powerfixed to slab

Door opening

100mmmin.

100mmmin.

NOTE: Lintel must be fully glued to adjacent panels.

Detail 12.6.2 Door opening – Type 2

Detail 12.6.3 E-Core Fire Door or similar for Type 2 Wall Systems

Fire rated metal door frame(fill as specified)

Fire and acoustic rated sealant to manufacturer's recommendations

Plasterboard as per system requirements

65mm hex head screws to door manufacturer's specifications

Steel frame or furring channel to manufacturer's specifications

50mm bugle head coarse thread screws at 300 to 450mm centres

Rivets at 300 to 400mm centres

136

– 17

1mm

Retaining strip

75mm Hebel Supercrete Panel

NOTE: All gaps between wall and frame to be filled with Hilti CP 611A intumescent firestop mastic or equivalent.

Detail 12.6.4 Door Nib

75mm Hebel Supercrete Panel

270mm min

14-10 x 150mm hex head coarse thread screw at 900mm max. centres and 100mm max. from panel ends (3 per panel min.)

Plasterboard asper systemrequirements

Fire rated metal door frame(fill as specified)

Door frame to manufacturers specifications

Detail 12.6.5 E-Core Fire Door or similar for Type 4 Wall Systems

Plasterboard 4mm dia. holes with 14-10 x 65mm hex head screws at 300 to 450mm centres

Laminated 50mm bugle head coarse thread screws at 300 to 450mm centres

Insulation

E-Core Fire door orequivalent

Rivets at 300 to 400mm centres

NOTE: All gaps between wall and frame to be filled with Hilti CP 611A Intumescent firestop mastic or equivalent.

Retaining strip 1.4m thick

Unfilled

75mm Hebel Supercrete Panel

75mm Hebel Supercrete Panel

Important:

1. All door frame installations and detailing to be approved by door frame manufacturer.

2. Continuously screw fix door frame to Hebel Supercrete Panel around perimeter of door opening.

3. CFG Concrete Ltd recommends core filling of the door frame for additional robustness.

4. Fix door frame at the base.

12.6 Door DetailsDetails to be read in conjuction with the current Hebel Supercrete Acoustic Wall Systems Design Guide, AWS 2009

Page 32: Hebel Supercrete AWS Design Guide

AWS 2009 32

Detail 12.7.1 Large Penetration in Wall

Detail 12.7.5 Fire Collar Penetration

75mm Hebel Supercrete Panel

Switch mounting plate

Electric switch

Neat rebate for switch

Fill penetration with fire and acoustic rated sealant

Neat cable penetration

15mm max.

Insulation as per system requirements

Plasterboard as per system requirements

50mm bugle head coarse thread screw

Detail 12.7.2 Power Switch Installation into Hebel Supercrete Panel

Insulation as per system requirements

Plasterboard as per system requirementsPlasterboard

as per system requirements

Seal cable penetration as per switch box manufacturer's requirements

Fire rated switch box

Electrical cables run in cavity

Fire and acoustic rated sealant

75mm Hebel Supercrete Panel

Detail 12.7.3 Power Switch Installation into Cavity

NOTE: Appropriate project consultant to approve installation detail to satisfy project’s acoustic and fire performance requirements.

Fire rated backing rod and appropriate sealant to fire collar manufacturer's specifications

Non fire rated backing rod and fire rated sealant to fire collar manufacturer's specifications

Fire collar as determined by appropriate consultant

Plasterboard as per system requirements

Secure fire collar to panel as per the fire collar manufacturer's specifications

Plastic Pipe

Insulation as per system requirements75mm Hebel

Supercrete Panel

Detail 12.7.4 Metal Pipe Penetration

Fire and acoustic rated sealant to manufacturer's specifications

Non fire rated backing rod

Cover plate

Neat penetration

Provide 400 x 400mm backblock fixed with laminating screws in single layer lining systems

Plasterboard as per system requirements

Metal pipe

Insulation as per system requirements

75mm Hebel Supercrete Panel

15mmmax.

Rondo deflection head powerfixed to slab

Opening900 x 400mm

Lintel (Hebel Supercrete

Panel)

Full height vertical panel

14-10 x 150mmhex head coarsethreaded screwHorizontal

panels

100mm min.

100mm min.

12.7 Penetration and Services DetailsDetails to be read in conjuction with the current Hebel Supercrete Acoustic Wall Systems Design Guide, AWS 2009

Page 33: Hebel Supercrete AWS Design Guide

AWS 200933

A1 Hebel Supercrete Panel Material Properties

Hebel Supercrete Panel Physical Properties

1) Nominal dimensions and profiles of standard and custom 75mm Hebel Supercrete Panel are shown in Section 8.

2) Standard 75mm Hebel Supercrete Panel has a single layer of steel reinforcement consisting of 4 longitudinal bars of 5mm diameter.

3) Custom 75mm Hebel Supercrete Panel has a single or double layer of steel reinforcement consisting of 4 or 5 longitudinal bars of 5mm diameter.

4) Nominal dry density = 510kg/m3.

5) Average working density = 663kg/m3 at 30% moisture content.

6) Average service life density = 561kg/m3 at 10% moisture content.

7) For custom Hebel Supercrete Panel average working density =707kg/m3 at 30% moisture content.

Hebel Supercrete Panel Strength Properties

1) Characteristic compressive strength, f ’m = 2.8 MPa.

2) Average compressive strength = 3.2 MPa.

3) Characteristic Modulus of Rupture, f ’ut = 0.60 MPa.

Hebel Supercrete Panel Fire Rating Properties

For FRR ratings of Hebel Supercrete 75mm Panel and AWS walls refer to fire opinions FCO-2073, FCO-2327 and WFRA 45771.3.

Hebel Supercrete Panel Acoustic Properties

75mm Hebel Supercrete Panel with no plasterboard or other lining has an STC = 37dB (refer to ATF-676 test and PKA-201006 opinion).

Appendix A

Hebel Supercrete Panel Thermal Properties

R-Value of bare 75mm Hebel Supercrete Panel with no plasterboard or other lining = 0.43 m2K/W at 10% moisture content.

Typical Thermal Calculations

Wall Type 1 R

Indoor air film 0.12

10mm Plasterboard 0.059

Insulation 2.2

Air space 0.14

75mm Hebel Supercrete Panel

0.43

Air space 0.14

Insulation 2.2

10mm Plasterboard 0.059

Indoor air film 0.12

Total R = 5.468

Wall Type 2 R

Indoor air film 0.12

10mm Plasterboard 0.059

75mm Hebel Supercrete Panel

0.43

Insulation 2.2

10mm Plasterboard 0.059

Indoor air film 0.12

Page 34: Hebel Supercrete AWS Design Guide

AWS 2009 34

A2 Proforma Architectural SpecificationThis specification should be adopted as a guide only, and shall be superseded by the contract specifications of the project.

* Insert or select appropriate specifications.

Scope

The contractor shall furnish all material and equipment required to satisfactorily complete the installation and jointing of the Hebel Supercrete Acoustic Wall System non-loadbearing wall where indicated in the contract specification and/or on the layout drawings.

Materials

All AAC material shall be 75mm Hebel Supercrete Panel as manufactured by CSR Hebel.

All accompanying fixings shall be as per the current Hebel Supercrete Acoustic Wall Systems Design Guide, AWS 2009 and/or the appropriate project consultant’s specifications.

All lining materials shall be plasterboard manufactured to meet the dimensional requirements of AS/NZS2588 ‘Gypsum Plasterboard’.

Steel frame components shall be those manufactured by Rondo Building Services Pty Ltd (or products of equivalent or better performance).

Levels of Finish

All framing, plasterboard lining, jointing and finishing shall be carried out to *Level ………Level of Finish, in accordance with AS/NZS2589.1 ‘Gypsum Linings in Residential and Light Commercial Construction – Application and Finishing’.

Wall System

The contractor shall supply and install Hebel Supercrete Panel and Acoustic Wall System non-loadbearing wall (table-system-wall type) *(……)-(……………)-(……), in accordance with the current Hebel Supercrete Acoustic Wall Systems Design Guide, AWS 2009, and shall satisfy the following performance criteria.

The wall shall have a Fire Resistance Rating *……/……/…… in accordance with the requirements of AS/NZ1530.4.

Installation shall be carried out to the level specified for a field acoustic performance of *STC……………using cavity infill of …………………fibreglass batts or equivalent.

Wall Framing

Wall framing shall consist of lipped steel studs *…………x…………x…………mm BMT installed at *………mm maximum centres into steel floor and ceiling

track *…………x…………x…………mm BMT. The gap between the Hebel Supercrete Panel and the framing shall be *………………mm (10mm minimum

NOTE: It is important that the project engineer approve the type, size and maximum spacing of the fasteners to meet the design load requirements.

PlasterboardCaution:

■ Fire rated installations must be fastener fixed. Adhesive is not permitted.

■ Adhesive does not constitute a fixing system by itself.

■ Adhesive daubs must never coincide with fastening points.

■ Stud adhesive MUST NOT be used on FIRE RATED or TILED WET AREA systems.

The Hebel Supercrete Panel wall/steel framing/timber framing shall be lined on the first side with one layer of *…………mm *………………… plasterboard. (followed by a second layer of *…………mm *………………… plasterboard.)

The Hebel Supercrete Panel wall/steel/timber framing shall be lined on the second side with one layer of *…………mm *………………… plasterboard. (followed by a second layer of *…………mm *………………… plasterboard.)

Plasterboard Fixing

All layers shall be fixed to the Hebel Supercrete Panel as specified for the relevant system, in the current Hebel Supercrete Acoustic Wall Systems Design Guide, AWS 2009.

All layers shall be fixed to the steel framing or timber framing as specified for the relevant system in the Plasterboard Manufacturers Installation Guide, Technical Literature, and Rondo Building Services Pty Ltd literature or steel frame manufacturer’s literature.

Caulking

*………fire rated polyurethane sealant / Promaseal® IBS™ Rod + *………acoustic rated polyurethane sealant must be used in fire rated systems where caulking is indicated, and installed in accordance with the manufacturer’s recommendations.

*………polyurethane sealant must be used when caulking * non-fire rated/fire rated wet areas, as indicated, and installed in accordance with the manufacturer’s recommendations.

Important

Any variation or substitution of materials or assembly requirements, or compromise in assembly may result in failure under critical conditions.

Page 35: Hebel Supercrete AWS Design Guide

AWS 200935

A3 Installation ChecklistChecklist to be read in conjunction with ALL Hebel Supercrete documentation including the Hebel Supercrete Technical Manual and the current Hebel Supercrete Acoustic Wall Systems Design Guide AWS 2009 and technical advice from CFG Concrete Ltd. Co-ordination and compliance with project consultant’s specification is compulsory.

BUILDING: ______________________________________________________________________________________________________

LEVEL: _______________________________________ GRID OR AREA: __________________________________________________

1. Has the specified ______________ mm head track been installed in accordance with project specifications? All gaps should be filled between the head track and concrete soffit with a fire and acoustic rated sealant. The deflection head should be overlapped where necessary. Ideally a continuous length of track should be used at the top of the panels.

2. Has the correct diameter IBS rod been used for the specified deflection gap? For a 15mm deflection gap, has a 22mm diameter Promaseal IBS been installed? The rod is not to be compressed by any fixing. Ideally the rod should be continuous, where the rod has to be spliced – the rod shall be overlapped a minimum of 200mm. Has the IBS rod been overlapped 200mm minimum at splices/joins? At the ends of walls, where panels abut concrete walls/columns, the IBS rod shall turn down a minimum of 400mm? Has the IBS rod been turned down 400mm minimum at the end of the wall?

3. Has the specified ______________ mm base track been installed in accordance with project specifications?

4. Panel Installation Has Hebel Supercrete Panel been installed? Has the Promaseal IBS rod been compressed the amount specified by the manufacturer? 7mm compression for the 22mm diameter IBS rod. Has Mortar been installed at the base of the panel? Has the panel been secured to the base track with a minimum of 14 – 10 x 65mm Hex Head screws (locate a minimum of 50mm from either end)?

5. Are the vertical joints glued with Adhesive? Is the joint width 2-3mm?

5a. Rigid Corner Joints Have, 14 – 10 x 150mm Hex Head screws or approved equivalent and Adhesive been used in accordance with Hebel Supercrete Acoustic Wall Systems Design Guide to form returns? Have the screws been located at 100mm minimum from either end of the panels and at 900mm maximum centres?

5b. Control Joints Install control joints at a maximum of 6m spacing to internal walls, a 10mm minimum allowance to be made for a foam backer rod and fire rated sealant or Promaseal IBS rod and acoustic sealant where applicable. Has a control joint been installed where the Hebel Supercrete panels abut concrete columns or walls? Has the specified foam backing rod and sealant been placed in the control joint?

5c. Damaged Panels Did Hebel Supercrete representative acknowledge that damaged panels were acceptable for repair?

5d. Cut Reinforcement Has the cut reinforcement been coated with the corrosion protection paint in accordance with Hebel Supercrete Acoustic Wall Systems Design Guide?

6. Have door jambs been installed (supplied by others) in accordance with the door manufacturer’s recommendations and Hebel Supercrete Acoustic Wall Systems Design Guide?

7. Has the specified plasterboard been fixed to the Hebel Supercrete Panel with screws nominated in the Hebel Supercrete Acoustic Wall Systems Design Guide?

8. Has specified steel stud frame been erected at the nominated offset from the Hebel Supercrete Panel wall? Has the frame been secured to the concrete in accordance with the project specifications? Has the correct insulation been installed in accordance with the manufacturer’s recommendations?

9. Has the specified plasterboard lining been installed and finished in accordance with manufacturer’s recommendations? Have the specified sealants been installed at the gaps between the plasterboard and concrete surfaces in accordance with manufacturer’s recommendations?

10. All Power outlets/switches offset by 600mm minimum? All services should be placed within the thickness of the furring channel or stud. All outlets/switches on the plasterboard and steel stud side of the wall shall be fully sealed.

SATISFACTORy ACTION REqUIRED (see notes)

INSTALLATION TASK/ITEM

Page 36: Hebel Supercrete AWS Design Guide

CFG Concrete LtdA Member of the CFGNZ Limited

67 Reid Rd, P.O. Box 2398Dunedin, New Zealand.Phone: +64 3 455 1502 Fax: +64 3 456 35870800 4 HEBEL (0800 443235)www.hebel.co.nz

The information presented herein is supplied in good faith and to the best of our knowledge was accurate at the time of preparation. No responsibility can be accepted by CFG Concrete Ltd or its staff for errors or omissions. The provision of this information should not be construed as a recommendation to use any of our products in violation of any patent rights or in breach of any statute or regulation. Users are advised to make their own determination of the suitability of this information in relation to their particular purposes and specific circumstances. Since the information contained in this document may be applied in conditions beyond our control, no responsibility can be accepted by us for any loss or damage caused by any person acting, or refraining from action as a result of this information. The systems detailed in this design guide are only to be used with Hebel Supercrete products manufactured by CSR Hebel Australia and distributed by CFG Concrete Ltd. This literature is not permitted to be used for other types of AAC, including Hebel Supercrete AAC from other manufacturers.

For your nearest distributor of Hebel Supercrete Productsvisit our website www.hebel.co.nz

Technical SupportCFG Concrete Ltd and its nationwide network of distributors offers technical assistance in New Zealand. Visit www.hebel.co.nz for your nearest distributor who will offer free estimating services; technical support to project architects, engineers, builders and owners. Distributors arrange for their Licenced Hebel Supercrete Panel Installers and Supercoat Coating Applicators to undertake the install and coating works. They also train and monitor these licensed personnel.

Health & SafetyInformation on any known health risks of our products and how to handle them safely is shown on their package and/or the documentation accompanying them.

Additional information is listed in the Material Safety Data sheet. To obtain a copy, telephone 0800 443 235

GuaranteeHebel Supercrete Autoclaved Aerated Concrete products and Supercoat coating products are guaranteed to be free of defect in material and manufacture.

Installation workmanship and coating application work is guaranteed by the licensed personnel who perform this work.

Substitution of this claddings’ listed components is not permissible and if alternative brands, materials or elements are used, this will void all guarantees.

This guarantee excludes all other guarantees and liability for consequential damage or losses in connection with defective cladding, other than those imposed by legislation.

Authorised DistributorFor further information on products and our New Zealand wide Distributor Network Phone 0800 4 Hebel or visit www.hebel.co.nz

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