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13.1 Hebel PowerPanel

The core component of Hebel PowerWall is the 75mm thick Hebel PowerPanel. The PowerPanel is manufactured in a range of stock sizes as detailed in the following table.

Table 13.1  Standard and Manufactured Panel Sizes

Panel Type Panel Weight (at 51kg/m2)
Length (mm) Length (mm)
300 600
Standard 1200 37
2400 37 74
2550 78
2700 42 83
2850 88
3000 46 92

Note:
1 Average PowerPanel weight calculated at 30% moisture content.

13.2 Top Hat

The top hats are used to fix the Hebel PowerPanel to the structural support framing. Three types of top hats can be used in Hebel PowerWall. These are FastStud 24TH42, Rondo Nº303, and Lysaght Topspan 22 shown in Figure 13.1. For alternative top hat types, the top hat manufacturer or project engineer will be responsible for approving the substitute product as adequate for performance requirements.

Fig. 13.1  Typical tophat

Fig. 13.2 Typical Hebel PowerPanel and Panel X-Section

Fig. 13.3  Hebel PowerPanel

NOTE

BTM: To locate the approximate location of reinforcing the smooth edge of the panel is the bottom (BTM).

Bars: 4x4mm Ø longitudinal & 6-8 transverse bars depending on PowerPanel length.

Tolerence: The width & thickness of the PowerPanels are manufactured to a tolerance of + or – 1.5mm.

Cutting: Panel to be no less than 270mm wide. Where it is unavoidable to install a panel larger than 270mm, (eg between windows) the panel must not be less than 100mm and be supported continuously along the length by tophats.

13.3 Timber or Steel Stud Framework

All timber or steel stud framework to be supplied and installed in accordance with relevant Australian standards and project engineer’s instructions.

13.4 Hebel Mortar

Hebel Mortar (supplied in 20kg bags) when required is used as a thick bed mortar base to provide a level base for PowerPanel installation as well as providing acoustic and fire protection at the base of the PowerPanels.

Fig. 13.4  Hebel Mortar

13.5 Hebel Adhesive

Hebel Adhesive (supplied in 20kg bags) is used for gluing the PowerPanels together at vertical and horizontal joints.

Fig. 13.5  Hebel Adhesive

13.6 Hebel Patch

Minor Chips or damage to PowerPanels are to be repaired using Hebel Patch (supplied in10kg bags).

Fig.13.6 Hebel Patch

13.7 Anti-corrosion Coating Agent

Steel reinforcing exposed on cut PowerPanels must be coated with a liberal application of Fentak Exposed Reinforcing Touch Up Paint (anti-corrosion agent).

Fig.13.6 Fentak Exposed Reinforcing Touch Up Paint

13.8 Flashing

In general, flashings shall be designed and installed in accordance with SAA – HB39 1997 – Installation Code for Metal Roofing and Wall Cladding.

13.9 Panel Support Packer

The PowerPanel support packer should consist of a durable material that will not degrade during the life of the structure.

13.10 Sarking

Hebel PowerWall may incorporate a sarking membrane between the top hats and steel stud support framing for condensation control or for improving the thermal insulation performance. Sarking must be designed and installed in accordance with AS/NZS4200 Part l Materials, and Part 2Installation.

13.11 CSR Bradford Insulation

Hebel PowerWall incorporates CSR Bradford Insulation materials.

Fig.13.7  Bradford Insulation

13.12 CSR  Gyprock Plasterboard

Hebel PowerWall incorporates Gyprock plasterboard on the internal stud side. The type, thickness and densities of plasterboard will be as per Hebel PowerWall requirements.

13.13 Backing Rod

Backing rod is used to enable correct filling of joints with sealant. It is recommended that backing rod be of open cell type to enable sealant to cure from behind. The diameter of backing rod must be appropriate for the width of the gap being filled.

13.14 Sealants

All gaps in internal and external junctions and movement joints must be caulked with appropriate polyurethane sealants. Sealants shall be installed in accordance with the sealant manufacturer’s instructions.

IMPORTANT

Sealants and primers (as required) must be compatible with the substrate material, such as flashings, Hebel PowerPanel, window frame material and coatings.

13.15 External Finishes

Fig. 13.8  Hebel PowerBase and PowerFinish

Hebel coatings are designed to achieve the perfect finish to any Hebel project, including the highly sought after smooth, Monolithic look.

For more information on coatings refer to the ‘Weatherproofing’ Section 10.0 of this design guide.

CSR Hebel does not recommend cement based site mixed renders be applied to Hebel PowerWall.

13.16 Fasteners & Fixings

1. Fixing of top hat to timber stud frame;

12-11x25mm Hex Head Type 17 screw

2. Fixing of top hat to steel framing;

10-16x16mm Hex Head Teks screw

3. Fixing of Hebel PowerPanel to top hat from inside of building;

14-10x65mm Hex Head Type 17 screw

4. Fixing of Hebel PowerPanel to top hat from outside of building.

14-10x100mm MP Bugle Head Type 17 screw

Plasterboard fixings

Fix the plasterboard to the steel studs in accordance with CSR Gyprock instructions.

Fig. 13.8 Standard Fixings Used in Hebel PowerWall

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14.1 Tools and Equipment

The basic tools required to assist in the installation of the PowerPanel are shown in Figure 14.1. These may be purchased through a CSR Hebel distributor and include:

1. Mixing bucket
2. Stirrer
3. Notched trowel
4. Sanding float
5. Panel lifters

Extra equipment will also be required and includes the following:

  • Power drill (clutch driven).
  • Power saw with metal or diamond tipped cutting blades.
  • Dust extraction system.
  • Sockets for screws.
  • Personal Protective Equipment (PPE) such as goggles, ear muffs/plugs and face mask, used when site cutting the PowerPanels.

Fig. 14.1  The Basic Tools and Equipment Requirements

14.2 Hebel PowerPanel Installation Sequence

1. Frames and Trusses Complete

Install sarking and wall wrap as specified

2.  Fix Top Hats

2 screws/stud
Check number of top hats required
Extras under openings

Check overlap at corners
Check detail around control joints, ensuring top hats are discontinuous at Control Joint locations

3.  Install DPC

Fix to bottom plate
Cover step completely
Lap at corners

4. Install Hebel PowerPanel

Corner PowerPanel installed first
3 screws from outside
Check PowerPanel orientation at corners
First PowerPanel vertical with level

Hebel Adhesive to vertical joints

Check number of screws per top hat
Check control joint locations

Site-cutting to suit
Coating of exposed reinforcement
Minimum panel width 270mm*

5.  Window Detail

Panel hard against window frame           Weather strip down sill

                                                                    Flashing behind PowerPanel

                                                                 Site-cut sill with slope

                                                                   Apply anti-corrosion agent

6.  Prepare for Coating

      Fill joints and patch any damage          Fill external screw holes as required

7. Coating

         Seal windows                                  Refer to specification from coating
Seal control joints                             manufacturer for further detail

14.3 Installation of Services

The installation of services in the building is very similar to the methods currently being used throughout the industry.

The gap between the PowerPanel and the frame, which nominally measures 20-25mm, is quite adequate to allow electrical services to be installed as usual. The electrical meter box can be face fixed to the outside of the PowerPanels, or alternatively, recessed into the stud frame through the PowerPanels. In the latter case, appropriate setout of the opening should also suit the 300mm module and all sides of the box should be sealed to the PowerPanels with an approved polyurethane sealant.

With regard to plumbing services, the hot and cold water pipes can be externally face fixed to the studs, if necessary. As Hebel PowerWall is not classified as cavity construction, this installation technique is satisfactory. The only difficulty occurs when the pipes are run vertically. In this case the pipes must be mounted between the studs, so as not to foul the horizontal installation of the top hats. Top hats are not to be cut to allow clearance for services.

Penetrations through the PowerPanel for services should be neatly filled and the joint sealed with a polyurethane sealant.

Fig. 14.2  Installed Piping Services Prior to the Installation of Hebel PowerPanel

Fig. 14.3  Neat Finishes of Installed Services

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