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)|
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
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
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.
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 2 – Installation.
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.
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.
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
Fix the plasterboard to the steel studs in accordance with CSR Gyprock instructions.
Fig. 13.8 Standard Fixings Used in Hebel PowerWall