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7.1 Overview

Hebel PowerWall can be subjected to a fire loading as the result of either an external fire source, or an internal fire source. When the wall requires a fire resistance level (FRL) rating, CSR Hebel provides the following guidance.

External Fire Source.

For an external fire source, the excellent fire resistance qualities of the Hebel PowerPanel cladding protects the structural support framing, and provides a high fire resistance level for Hebel PowerWall.

NOTE

The FRL rating of the wall can be affected by the penetrations and the method adopted to protect these penetrations. A fire collar with a –/120/120 FRL rating will govern the FRL of the wall, even if the wall configuration has a FRL rating of –/180/180. Where required, the performance of the external coating when subjected to a fire loading shall meet the appropriate performance requirements outlined in the BCA. Joints & gaps need to be appropriately fire rated. Eg. vertical control joint will need fire rated sealant & horizontal joints must be blocked with compressible fire rated material.

Fire Certificates & Reports.

Copies of the test reports and/or opinions can be obtained by contacting CSR™ Hebel™. A certificate of test FSV0356 is provided in Appendix D of this guide. Hebel™ PowerWall™ achieves a FRL of 240/180/180.

Internal Fire Source

For an internal fire source the studs must be protected by the internal wall linings. Refer to CSR™ Gyprock Red Book for specifications.

External Walls in Fire – BCA Provisions

Where necessary, the designer and builder should ensure the structural support framing, its connections as well as the Hebel PowerPanel installation are satisfactory when subjected to fire conditions. The BCA Vol 2 (Part 3.7.1) outlines provisions for external walls for fire resistance in a residential building where the external wall is less than 900mm from an allotment boundary or 1.8m from another building on the same allotment. If this occurs an FRL of not less than 60/60/60 is required from the outside.

7.2 Fire Performance of Hebel PowerWall

Hebel PowerWall was tested at the CSIRO, North Ryde and a Fire Resistance Level (FRL) of 240/180/180 was achieved (refer to Appendix D). Note, the fire source was on the PowerPanel side. This excellent result enables Hebel PowerWall to be used in the following applications:

  • Walls on zero line allotment blocks.
  • Multi-storey residential dwellings - external walls.
  • Commercial developments.
  • Infill PowerPanels.

NOTE

In the above applications, each PowerPanel should be screwed as specified in this guide, except a minimum of three screws should be installed through the middle top hat into each PowerPanel™ (refer to the fire test certificate in Appendix D).

Fig. 7.1 Bushfire Area

7.3 Bushfire Areas

BCA 2006 Vol. 2 Part 3.7.4 describes the provisions applicable to construction in bushfire prone areas. The reference code is AS3959. Hebel PowerPanel™ is non-combustible and suitable for all bushfire exposure levels (refer to Appendix A.6).

7.4 Design Considerations

Fire Stop Penetrations

Penetrations through Hebel PowerPanel to accommodate pipework, electrical cabling or ductwork will have to be protected (fire stop), to prevent the spread of fire through the penetration. The penetration can be protected with proprietary products, such as:

 

  • Fire rated sealants.
  • Fire collars and intumescent wraps.
  • Fire rated mortars.
  • Fire rated pillows.
  • Fire rated switch boxes

CSR Hebel recommends contacting the manufacturer to obtain the appropriate product/solution and installation method for the application and wall configuration.

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8.1 Building Code of Australia (BCA)

The BCA is available in two volumes which align with two groups of ‘Class of Building’:

  • Volume 1 – Class 2 to Class 9 Buildings; and
  • Volume 2 – Class 1 & Class 10 Buildings – Housing Provisions.

Each volume presents the Performance Requirements for the efficient use of energy for internal heating and cooling in buildings. The majority of changes have been associated with the Housing Provisions.

The Performance Requirements for energy efficiency ratings are dependent upon the form of construction (i.e. walls or floors), Class of Building, and the type of areas being separated. The performance requirement is a value that is the Total R-Value, which is the cumulative total of the individual R-Values of the building system components.

8.2 Hebel PowerWall

One of the primary design objectives in planning a building is to provide a cost effective comfortable living/ working environment for the building’s inhabitants. Exploiting the inherent thermal mass and insulation qualities of Hebel enables the designer to achieve this objective.

Several international comparative studies have been conducted to investigate the benefits of incorporating AAC walls in place of conventional wall systems.

A common trend was the lower heating and cooling energy consumption and smaller mechanical equipment required to maintain a comfortable living environment, especially with regards to regions of mainly cold weather. The excellent performance was the result of the three characteristics – thermal mass, thermal insulation, and the air tightness of the construction.

The level of insulation provided in a wall is determined by the required Total R-Value. The higher the required Total R-Value the greater the insulation provided. Hebel PowerWall incorporating CSR Bradford insulation can provide the R-Value ratings outlined in Table 8.1.

8.3 Thermal Insulation

It is recommended that insulation materials be installed to enhance thermal insulation properties and occupant comfort. Insulation also improves the acoustic performance of the wall against outside noise.

The BCA provides Deemed-to-Satisfy Provisions for compliance and installation of the various types of insulation. The insulation should be installed in Hebel PowerWall such that it forms a continuous barrier to contribute to the thermal barrier. All insulation installed in Hebel PowerWall must comply with: AS/NZS4859.1; or AS2464.3 for loose fill insulation.

8.4 Air Tightness

As outlined in Section 8.1 the thermal performance can be influenced by many factors. Most of these are related to the design decisions and properties of the adopted materials. Construction practices can also significantly affect the performance with poor sealing, resulting in drafts. The tight construction tolerances of AAC provide a wall with low air infiltration rate. Testing at the CSIRO (Test Report DTM327) on Hebel blockwork with thin bed adhesive joints has determined an air infiltration rate of 0.3L/s (0.014% of internal volume). For PowerPanels having fewer thin bed adhesive joints, a rate less than this could be achieved.

8.5 Sarking

As well as controlling condensation and acting as an air barrier, a sarking can be used to significantly improve the thermal insulation and energy efficiency performance of a building solution. Sarking layers can alter the performance of the cavity by providing a reflection side. The design of the sarking arrangement is complex and should be performed by the appropriate project consultant.

Where the sarking layer provides a weatherproofing function, the sarking material must comply with AS/NZS4200 Parts 1 and 2.

Where sarking is installed in the PowerWall, panels must be fixed from the outside.

Table 8.1  Energy Efficiency

The following tables show the performance levels required for walls and floors under the BCA and the thermal performance of the Hebel PowerWall system.

Climate Zones 1 2 3 4 5 6 7 8
Multi-Residential Class 2, 3, 4 & 9c building
Minimum required R-Value for walls R1.4 R1.4 R1.4 R1.7 R1.4 R1.7 R1.9 R2.8
Minimum added R-Value of insulation 0.49 0.49 0.49 0.79 0.49 0.79 0.99 1.89
Minimum complying PowerWall system 102 102 102 103 102 103 103 105
Detached Houses Class 1 & 10a buildings
Minimum required R-Value for walls R1.9 R1.9 R1.9 R2.2 R1.9 R2.2 R2.4 R3.3
Minimum added R-Value of insulation 0.99 0.99 0.99 1.29 0.99 1.29 1.49 2.39
Minimum complying PowerWall system 103 103 103 104 103 104 104 105
Hebel
PowerWall
System
Added R-Value of insulation for system variations: Additional
Insulation
Total
System
PowerWall 101 2-3mm skim render/coating system • 75mm thick Hebel™ PowerPanel™ • 115mm wall nonventilated cavity (non-reflective) • Min. 70mm frame • 10mm Gyprock plasterboard CD None R0.91
PowerWall 102 Bradford EnviroSeal single sided reflective foil laminate, no insulation R0.62 R1.53
PowerWall 103 Bradford EnviroSeal metal roof/wall double-sided reflective foil laminate, no insulation R1.04 R1.95
PowerWall 104 Bradford Gold Insulation R1.5 wall batts only R1.50 R2.41
PowerWall 105 Bradford Gold Insulation R2.5 wall batts only R2.50 R3.41
PowerWall 106 Bradford EnviroSeal metal roof/wall double-sided reflective foil laminate, plusBradford Gold Insulation R2.5 wall batts R2.83 R3.74

 

Notes:

  • Refer to BCA for state & territory variations.
  • Refer to BCA for alternative means of satisfying the required performance levels.
  • Refer to CSR Bradford product literature for design & installation requirements for the nominated reflective foil laminates and insulation.

Energy Rating Software

Energy legislation (5 stars) is changing every year and ratings software is changing to keep up. Combine this with all the variable elements in a house such as window sizes, floor space and house orientation and you have a moving landscape. Hebel provides a great springboard for walls and floors in these rating systems due to its unique thermal properties of insulation AND mass. When rating in FirstRate, AccuRate, BASIX and BERS select AAC as the wall and floor option and see why Hebel is fast becoming the all star performer. Hebel can help your project achieve 5 stars and beyond.

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DURASCAPE IS A 9MM THICK FIBRE CEMENT BASE SHEET WITH A 5MM WIDE SHIPLAP JOIN GIVING A SUBTLE VERTICAL SHADOW LINE WHILST COVERING LARGE AREAS. DURASCAPE CAN THEN BE FINISHED WITH ROLL-ON TEXTURED PAINT ON SITE CREATING A RENDERED LOOK.

DURASCAPE IS QUICK TO INSTALL AND CAN BE USED IN SINGLE STOREY AND MEDIUM HEIGHT INSTALLATIONS WHERE A LARGE PANEL LOOK IS REQUIRED.

DURASCAPE BASE SHEETS:

  • GIVE A SUBTLE VERTICAL SHADOW LINE
  • ARE LIGHTWEIGHT AND DURABLE
  • QUICK TO INSTALL BECAUSE IT ELIMINATES THE NEED FOR TAPED AND FILLED JOINTS
  • PANELS ARE NOT AFFECTED BY TERMITES, AIR, STEAM, SALT OR SUNLIGHT

APPLICATIONS

Durascape is a strong and durable base sheet which has a subtle vertical ship lap joint that is suitable for finishing with a textured paint.

Durascape is suitable for low to medium rise buildings and can be used on both timber and steel framed buildings. It is also ideal for renovations and alterations to existing dwellings.

ADVANTAGES

  • Gives a subtle 5mm vertical shadow line
  • Is lightweight and durable
  • Quick to install because it eliminates the need for taped and filled joints and vertical set joints
  • Panels are not affected by termites, air, steam, salt or sunlight

ENERGY EFFICIENCY CONSIDERATIONS

Energy efficiency requirements have been introduced into the Building Code of Australia (BCA) for both commercial and residential buildings. Thermal heat transfer into and out of the building envelope will effect the running cost of the building and careful consideration of thermal heat transfer needs to be addressed by the architects, engineers and building designers. Thermal bridging through steel framing will diminish the total R-Value; thermal conductance, of the wall. Thermal breaks are required for steel framed buildings and should be installed between the steel frame and the Durascape panels. Thermal break tapes should have a minimum R-Value of 0.2.

PRODUCT INFORMATION

Durascape panels are manufactured from Portland cement, finely ground silica, cellulose fibres and water. Panels are cured in a high-pressure steam autoclave to create a durable, dimensionally stable product.

Durascape panels are manufactured to the Australian / New Zealand Standard AS/NZS 2908.2-2000 Cellulose-Cement Products, Part 2: Flat sheets and Durascape is classified as Type A-Category 2.

FIRE RESISTANCE

BGC Fibre Cement products have been tested in accordance to Australian Standard AS1530.3.

These tests deemed the following Early Fire Hazard Indices:

/ Ignition Index                                            0
/ Spread of Flame Index                            0
/ Heat Evolved Index                                  0
/ Smoke Developed Index                         0-1

DURABILITY

BGC Durascape physical properties make it a very durable product.

/ Durascape panels are immune to permanent water damage in both short and long-term exposure.

/ Durascape panels will not rot or burn and are unaffected by termites, air, steam, salt and sunlight.

/ Durascape panels are not adversely affected over a temperature range of 0°C to 95°C.

Vapour permeable sarking must be installed in accordance with the AS/NZS 4200.2 – ‘Pliable building membranes and underlays – Installation’ and the sarking manufacturers’
guidelines. The sarking should have the following properties:

/ Vapour barrier – low or medium
/ Water barrier – high

Vapour permeable sarking is used to prevent moisture ingress by acting as a drainage plane whilst enabling water vapour build up from inside the frame to escape.

THERMAL CONDUCTIVITY

Durascape panels have relatively low thermal conductivity:
R-value. At Equilibrium Moisture content the approximate R-Value of Durascape is;- 0.55 W/m°C.

WEATHER RESISTANCE / FREEZE THAW

Durascape conforms to the Building Code of Australia (BCA) requirements for external wall applications. Durascape facade system has been tested to AS/NZS 4284 Testing of Building Facades.

Durascape subject to freeze/thaw conditions must be painted. Durascape should not be used in situations where it will be in direct contact with snow or ice for prolonged periods.

PANEL SIZES AND MASS

THICKNESS  mm MASS KG/M2 WIDTH mm LENGTH mm
2450 3000
9 12.5 900 X X
1200 X X

SHEET TOLERANCES

/ Width +0/-2mm
/ Length +0/-2mm
/ Thickness +10%/-0%
/ Diagonals difference (max) 2mm
/ Edge straightness deviation (max) 1mm

HANDLING AND STORAGE

Durascape must be stacked flat, up off the ground and supported on equally spaced (max 400mm) level gluts. Care should be taken to avoid damage to the ends, edges and surfaces.

Sheets must be kept dry. When stored outdoors it must be protected from the weather. Sheets must be dry prior to fixing, jointing or finishing.

EXTRA CARE MUST BE TAKEN AT THE SHEET EDGES TO PREVENT CRACKING OF THE SHIPLAP JOIN.

COASTAL AREAS

The durability of galvanised nails and screws used for exterior cladding in coastal or similar corrosive environments can be as low as 10 years.

For this reason BGC recommend the use of stainless steel fasteners within 1km of the coast or other large expanses of salt water.

ACCESSORIES AVAILABLE FROM BGC

EPDM FOAM GASKET
(Used to prevent moisture ingress at sheet joins).
25m  
INTERNAL CORNER 3000mm  
EXTERNAL CORNER 3000mm  
HORIZONTAL FLASHING 3000mm  

 FASTENERS

DURASCAPE TO TIMBER FRAME

2.8 x 30mm Fibre Cement Nail (minimum Class 3 corrosion resistant)

2.8 x 40mm Gun Nail (minimum Class 3 corrosion resistant)

/ Screws should be countersunk 1.5mm and filled with BGC Exterior Finishing Compound or Epoxy sealer such as Megapoxy P1, Hilti CA125 or Hilti CA273 and sanded flush to provide a flat surface for finish coating.

/ Nails must be driven flush to the panel surface.

DURASCAPE TO STEEL FRAME

To Steel – 0.75BMT
No 8 x 30mm Countersunk Self Drilling (minimum Class 3 corrosion resistant)

To Steel – 0.8-1.6BMT
8 x 32mm Wingtek Self Embedding Head Screw (minimum Class 3 corrosion resistant)

CONSTRUCTION DETAILS

FRAMING

Durascape panels can be installed vertically to both timber and lightweight steel frames. Ensure that the frame is square and work from a central datum line.

The frame must be straight and true to provide a flush face to receive the panels.

BGC recommend a maximum tolerance of 3mm-4mm in any 3000mm length of frame.

Durascape will not straighten excessively warped or distorted frames and any warping may still be visible after Durascape is applied. Warped framing will require remedial action.

FRAME STRAIGHTNESS

TIMBER FRAMES

Use of a timber frame must be in accordance with AS1684 – Residential timber-framed construction and the framing manufacturers’ specifications.

Use only seasoned timber. Do not use unseasoned timber as it is prone to shrinkage and can cause sheets and frames to move up.

“Timber used for house construction must have the level of durability appropriate for the relevant climate and expected service life conditions including exposure to insect attacks or to moisture which could cause decay” – Reference AS 1684.2.

The framing width at sheet joints must be a minimum of 45mm. The intermediate support studs should be a minimum width of 35mm.

LIGHTWEIGHT STEEL FRAMES

Use of steel frame must be in accordance with AS3623 – Domestic metal framing and the framing manufacturers’ specifications.

Framing members must have a Base Metal Thickness (BMT) between 0.50 to 1.6mm. The steel framing must have the appropriate level of durability required to prevent corrosion.

The framing width at sheet joints must be a minimum of 50mm. The intermediate support studs should be a minimum of 64 x 35mm.

MAXIMUM STUD & FASTENER SPACING

GENERAL AREAS OF WALLS (MM) WITHIN 1200MM OF BUILDING EDGES (MM)
Wind Classification
AS4005
Stud spacing (mm) Fastener Spacing Stud Spacing Fastener Spacing
N1, N2, N3, N4 600 200 600 200
N5 450 200 300 150
N6 450 150 300 125
C1, C2 600 200 600 200
C3 450 200 300 150
C4 450 150 300 125

INSTALLATION

FASTENER POSITIONING

Durascape panels should be installed vertically with all sheet edges fully supported. The centre joints must coincide with the centre lines of the framing member and all sheets should be installed in one direction.

APPLY EPDM FOAM GASKET

At every vertical joint, fix a continuous strip of EPDM Foam Gasket to the vapour permeable sarking along the stud.

This assists to prevent the ingress of moisture at the sheet joins.

SHEET EDGE POSITION

Position the underlap sheet on every stud 3mm past the centre of the stud to ensure the fasteners fixed at the edge of the sheet have adequate distance into the stud.

As detailed on p6, there are several different fasteners that can be used to fix Durascape panels.

FIBRE CEMENT NAIL FIXING – TIMBER FRAME

FLUSH SCREW – LIGHTWEIGHT STEEL FRAME

COUNTERSUNK SCREW – LIGHTWEIGHT STEEL FRAME

To fix the first sheet, set in place ensuring the required edge distances are maintained.

FIX FIRST SHEET

Once both sheets are fixed, check the joint for gaps and fill with additional sealant if required.

FIX NEXT SHEET

Apply of continuous 4mm bead of sealant to the edge of the shiplap join.

APPLY SEALANT

INSTALLATION DETAILS

The architectural intent and details of buildings vary from one designer to the next, and the variety of facade details would be impossible to catalogue.

The detail diagrams following are intended to assist the designer in achieving a high quality weather resistant Durascape installation.

The designer should not digress from the specification set out in this manual.

The detail diagrams following are intended to assist the designer in achieving a high quality weather resistant Durascape installation.

SLAB EDGE/EAVE JUNCTION

EXTERNAL CORNER – SEALANT OPTION

EXTERNAL CORNER – STEEL

INTERNAL CORNER – SEALANT OPTION

INTERNAL CORNER – STEEL

WINDOW HEAD

WINDOW SILL

WINDOW JAMB

VERTICAL BUTT JOINT

 LOWER FLOOR JUNCTION

 UPPER FLOOR JUNCTION

HORIZONTAL JUNCTION 1

HORIZONTAL JUNCTION 2

THERMAL BREAKS

Thermal breaks are required for steel framed buildings, in walls enclosing habitable and or usable spaces. Careful consideration of thermal heat transfer and the position of thermal breaks need to be addressed by the architects, engineers and building designers.

Balustrades, parapets, and other non-enclosing wall elements may not require thermal bridging, except where the possibility of high thermal heat transfer exists throughthe steel CFS sections to the main structural steel element of the building.

MOISTURE MANAGEMENT

Designers, specifiers and builders have a duty of care to identify moisture-associated risks with any individual building design.

Wall construction design should consider both the interior and exterior environments of the building to effectively manage moisture. Special consideration should be given to buildings that are in extreme climates or at higher risk of wind driven rain.

In addition, all wall openings, penetrations, junctions, connections, window heads, sills and jambs must incorporate appropriate flashing for waterproofing. All other components, materials and installation methods used to manage moisture in walls should comply with the relevant standards of the Building Code of Australia (BCA).

WARRANTY

BGC warrants its products to be free from defects caused by faulty manufacture or materials. If any of its products are so defective the company will at its option, repair or replace them, supply equivalent replacement products or reimburse the purchase price.

This warranty shall not apply to any loss or consequential loss suffered through or resulting from defects caused by faulty manufacture or materials.

Fittings or accessories supplied by third parties are beyond the control of BGC and as such is not warranted by BGC.

BUSHFIRE AND BOUNDARY WALL AREAS

BGC Durascape is eminently suited for both bushfire and boundary wall applications in residential and multi residential buildings.

BGC Durascape can be used as a stand alone product to achieve up to BAL 40 when fixed direct to frame as per the fixing instructions in this manual.

BGC Durascape when used in conjunction with BGC 16mm Wet Area Fireboard will comply with the requirements of AS3959:2009 and AS1530.4 to achieve BAL FZ>10 as well as 60 minute and 90 minute boundary wall systems.

BUSHFIRE AS3959:2009 APPLICATIONS

AS3959:2009 sets out a series of Bushfire threat levels to buildings described as BAL (Bushfire Attack Levels) as follows:
BAL-Low, BAL-12.5, BAL-19, BAL-29, BAL-40 or BAL-FZ (Flamezone).

BGC Durascape may be used to achieve a BAL-40 or BAL-FZ>10 when used in conjunction with 16mm Wet Area Fireboard.

BOUNDARY/EXTERIOR WALLS

BGC Durascape in conjunction with BGC 16mm Wet Area Fireboard can achieve both 60/60/60 and 90/90/90 FRL fire ratings from the outside as required by the BCA.

Where an exterior wall is required to achieve 60/60/60 FRL (Fire Resistance Level) from the outside, 1 layer of 16mm BGC Wet Area Fireboard installed with BGC Durascape over the Wet Area Fireboard will meet minimum BCA requirements.

Similarly 2 layers of 16mm BGC Wet Area Fireboard used in conjunction with BGC Durascape will achieve 90/90/90 from the outside.

NOTE: All external walls must have sarking beneath the BGC Durascape No adhesives are to be used when installing Wet Area Fireboard and the BGC Durascape. Nails or screws must be used.

For more information please contact your nearest BGC Fibre Cement office.

BOUNDARY WALL SYSTEM

BGC FIBRE CEMENT IS A PROUD AUSTRALIAN OWNED MANUFACTURER OF FIBRE CEMENT PRODUCTS.

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