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csr power panel

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1.0 Introduction

CSR Panel Systems is a division of CSR Building Products Limited, one of Australia’s leading building products companies.

CSR Panel Systems manufactures Hebel Autoclaved Aerated Concrete (AAC). The AAC in Hebel products is manufactured from sand, lime and cement to which a gas-forming agent is added. The liberated gas expands the mixture, forming extremely small, finely dispersed air pockets, resulting in lightweight aerated concrete.

CSR Panel Systems has manufactured Hebel products that have won wide acceptance as innovative and environmentally preferable building materials. This is due to their lightweight nature, excellent thermal, fire and acoustic properties and design versatility. These inherent properties of Hebel products help achieve quick and cost efficient construction practices as well as providing for comfortable operating environments inside the buildings all year round.

Build a premium home with Hebel PowerBlock 

Hebel PowerBlocks are large AAC Blocks with a standard face dimension of 600mm x 200mm, laid in much the same way as bricks but using Hebel Adhesive to form a monolithic structure. Typically, external walls use a single skin of 250mm thick blocks while internal, non-loadbearing walls use 100mm thick blocks. Hebel’s tight manufacturing tolerances deliver beautifully flat, true surfaces that are easily rendered and painted.

Walls built with Hebel PowerBlock are strong and durable, providing the security of solid masonry coupled with exceptional thermal and acoustic insulation properties. With over three times the thermal resistance of double brick, Hebel PowerBlocks exceed the Building Code of Australia (BCA) for energy efficiency regulations for zones 1,2, 3 and 5 without the need for additional bulk insulation.

Hebel PowerBlocks are non combustible and can achieve an Fire Resistance Level (FRL) of up to 240/240/240.

For detached houses, this is well above the requirements for building right up to the boundary line and making Hebel an ideal choice for bushfire prone areas.

Compared to traditional double brick construction, Hebel PowerBlock walls can be laid much faster, saving building time and costs. Building with Hebel Blocks may create more internal floor area for the same building dimensions.

Hebel Lintels can be used over windows, doors and garage door openings. Hebel also supplies sill blocks for under windows to complement the overall look of your home.

Fig 1.1 Isometric Concept House

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2.0 Benefits

The many benefits of using Hebel PowerBlocks include:

Solid and strong:

Hebel PowerBlocks are made from Autoclaved Aerated Concrete (AAC), a strong, solid masonry building material with the advantage of being 25% the weight of conventional concrete.

Acoustic Performance:

Significantly reduced sound transmission from room-to-room.

Thermal Resistance:

Unique thermal properties result in a more stable inside temperature, reducing the energy
required to heat and cool your home, thereby reducing energy bills.

Environmentally friendly:

73% less embodied energy and 61% less greenhouse gas emissions than comparative masonry products*.

*Source: LCA Report GECA 2006

Fire Protection:

Non-combustible blocks with frameless construction deliver superior fire resistance. Hebel PowerBlock systems also allow you to build right up to your boundary line.

Pest resistance:

Not a food source for termites or vermin and no cavity construction eliminates the chance of harbouring pests.

Design Freedom:

Hebel PowerBlock Wall Systems provide absolute freedom to design and build your ultimate dream home – without compromise.

Technical Support:

Competent technical support through Hebel distributors.

Energy Efficiency

The unique combination of thermal resistance and thermal mass make building with Hebel a smart choice for meeting Australia’s stringent building regulations.

The thermal performance of a building depends on a number of factors such as orientation and size and aspect of windows. The R-Value of walls and floors can significantly affect the energy-rating outcome of dwellings. A 250mm Hebel PowerBlock has 3 times the R-Value of a cavity brick wall (BCA Vol. 2 Figure 3.12.1.3). The use of Hebel in walls and floors will provide increased thermal performance that can allow more flexibility with other design aspects of a building.

The thermal efficiency of Hebel systems will also reduce the reliance on heating and cooling appliances. The combined effects of running a heater less in winter and fans or air conditioning less in summer can have a big impact on energy costs and the environment.

Single Skin Construction

The AAC masonry constructed from Hebel PowerBlock products is called “Plain Masonry” and the blocks are masonry units referred to as a “Solid Unit”. The type of solid unit is “Autoclaved aerated concrete masonry unit” complying with AS/NZS 4455 – Masonry Units and Segment Pavers.

The larger face dimension and being a single skin, Hebel PowerBlock walls are erected quickly when compared to double brick construction.

Image 2.1:  Hebel PowerBlock home

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9.0 Construction Notes

General Notes

1. These notes and details are to be read in conjunction with the project’s contract documentation.

2. All materials and workmanship shall be in accordance with this Installation Guide, the current edition of the Hebel Technical Manual and other Hebel documentation.

3. Refer to architectural drawings for all setting out dimensions.

4. Do not scale drawings, use written dimensions.

5. Should any omission, penetration, cutting of panels, discrepancy or fault exist, contact the designer immediately for a decision before proceeding with work.

6. All load-bearing walls, bearing on Hebel floor panels, shall be supported separately in accordance with the project engineer’s design.

7. Hebel accepts no responsibility for the design or selection of supporting walls, lintels, beams, columns or other structural members.

8. Corrosion protection of all structural steelworks shall be specified by the project engineer or architect.

9. The temporary restraint of walls is the responsibility of the builder or installer.

10. PowerBlocks on site should be protected against rain and water saturation. This can best be achieved by leaving the shrink-wrap cap on the top of pallets and covering the top of blockwork if rain threatens. PowerBlocks should not be laid in the rain.

IMPORTANT
12. Ensure engineering tie-down rods are present and located in accordance with the engineer’s documentation.

13. Ensure control joint locations are marked out in accordance with the engineering documentation.

Fig 9.1:  Wall Construction Diagram

Coatings

Table 9.1 details Hebel recommendations for Coating System options for Low Rise and Detached Residential construction to deliver a durable, monolithic appearance.

Hebel and Dulux Acratex have developed coating systems designed specifically for the Hebel AAC substrate and warrant these systems for 7 years. Performance requirements for alternate system options are provided. In such circumstances, the project specifier must satisfy themselves that systems are engineered and suitable for relevant project requirements.

General purpose, site or pre-bagged sand and cement renders must not be used on Hebel PowerBlock walls, owing to potential variability and unsuitability of formulation for Autoclaved Aerated Concrete (AAC).

Conventional exterior low build paint systems must not be used, as their ability to accommodate normal expansion and contraction in order to maintain a crack free protective layer is not assured.

Refer to “High Performance Coating Systems” brochure on the website, for more information.

Reinforcing Mesh Installation

Fully meshing all rendered Hebel surfaces using alkali-resistant glassfibre mesh is recommended to assist in maintaining render integrity and minimising consequential cracking. The minimum requirement is to mesh at corners of wall openings (doors and windows) to minimise corner cracking. The mesh should be embedded into the wet first pass of Hebel HighBuild.

Linings

Plasterboard can be direct fixed to internal Hebel PowerBlock walls. It is recommended that battens be used behind plasterboard linings on the inside surface of external walls. Fibre Cement sheet linings must be installed on battens.
Table 9.1 Coating systems for Hebel PowerBlock

Primer Acrylic
Texture
Body
Coat
Finish
Coats
Hebel
Product
Finish
Style
Surface
Aignment
Base
Render
or
Levelling
Coat
Product
Description
&
Perfor
-mance
Guide
Dulux
AcraTex
Specifi
-cation
Product
Descri
-ption &
Perfor
-mance
Guide
Dulux
®AcraTex
®Specifi
-cation
Product
Descri
-ption &
Perfor
-mance
Guide
Dulux
AcraTex
Specifi
-cation
Comment
PowerBlock™ Uniform
Sand
Texture
profile
≤3mm Hebel
HighBuild™
(Render)
Relevant
to
coatings
supplier
recommend
-ations
AcraPrime
501/1
OPTION 1:
1-2mm
Acrylic
Texture
Trowel
applied
Type:
AS4548.4
Polymer
content (dry):
9% min.
Tuscany
or
Coventry
Coarse
Elasto
-meric
Membr
-ane
Type:
AS4548.1
Min DFT:
150 micron
Acra
Shield
Matt
or
Elasto
-meric
201
2nd
coat
Elasto
-meric
Membr
-ane
recomme
-nded
depen
-dant
on
project
comple
-xity
eg.
unbro
-ken
broad
wall,
scaffo
-lding
or
cutting
in
detail
and
coastal
areas
OPTION 2:
Depen
-dant
on
speci
-fier
appro
-val:
Sponge
finish
-ing
of
Hebel
High
-Build™
to
a
project
appro
-ved
stand
-ard;
plus
Elasto
-meric
Membr
-ane
finish
-ing
system.
Elasto
-meric
Membr
-ane
Type:
AS4548.1
Min.
DFT:
250
micron
Elasto
-meric
201
Hebel
recomm
-ends the
installa
-tion
of
1-2mm
Acrylic
Texture
Coat
over
the
render
base
coat
provi
-ding
impro
-ved
consist
-ency
of
finish,
system
flexibi
-lity and
durabi
-lity.

PowerBlock Laying Procedure

1. First Course

a. Mix Hebel Mortar according to the directions on the bag.

b. Mix Hebel Adhesive according to the directions on the bag.

c. Lay a DPC (damp proof course) slip joint membrane at the base of all external and internal walls to allow for differential movement between the blocks and the slab/ footing. Cut the DPC around tie rods as required. The DPC must be installed on the slab/footing prior to the application of Hebel Mortar.

d. Lay Hebel Mortar to get first course level and plumb. Accurately position a block and tap into place with a rubber mallet. Ensure that the block is level in all places.

e. All loose particles and dust must be brushed from the base and vertical end surfaces of all first course blocks before bedding in Hebel Mortar and applying Hebel Adhesive.

f. Apply Hebel Adhesive to the perpend of the base blocks using a Hebel notched trowel that matches the block thickness. Ensure full width coverage with 2-3mm final joint thickness.

g. Position the next block vertically adjacent the first block. Place the block down into position and gently tap the block end horizontally with a rubber mallet to fully close the vertical joint.

h. Tap the block vertically into the base mortar and level with the first block.

i. Repeat until the first course is complete.

j. Bore holes in blocks for tie-down rods using a 40-50mm auger bit and place over rods where required. Rod must be central in hole.

2. Second and Subsequent Courses

a. All loose particles and dust must be brushed from the top of the first course before applying Hebel Adhesive.

b. Apply Hebel Adhesive to the horizontal surface using a Hebel notched trowel that matches the block thickness.

c. Overlap the block joints a minimum of 100mm over joints in the previous course. Normal practice is to overlap by thickness of the intersecting wall.

d. Install wall ties where required, locating centrally accross block thickness and bed into the Hebel Adhesive.

e. Position the first block in the second course and gently tap accurately into place with a rubber mallet. Joints must be 2-3mm thick.

f. Apply Hebel Adhesive to the perpend of the first block. Position the next block vertically adjacent the first block. Place the block down into position and tap the end with the rubber mallet to fully close the perpend joint. Joints must be 2-3mm thick.

g. Tap the top of the block until level with the previous blocks laid.

h. Repeat for subsequent blocks.

i. Excess adhesive should be cleaned off the block face at the end of each course within 1-2 hours.

j. Large holes can be patched using Hebel Patch in accordance with the directions on the bag.

k. Bore holes in blocks for tie-down rods using a 40-50mm auger bit, and place over rods where required. Rod must be central in hole.

l. Where required construct a bond beam in the top course of loadbearing walls. Minimum dimension is 100mm wide x 200mm high. Use minimum 50mm thickblocks each side to form up bond beam. Reinforcement to be minimum 2x N12 deformed bars. Refer to Floor Panel Note 2 for grout specification.

m. Where required construct a ring beam in the top course of the non-loadbearing walls. Cut/rout 60mm x 60mm recess and place 1x N12 deformed bar centrally. Refer to Floor Panel Note 2 for grout specification.

3. Finishing

a. Ensure that all perpends are completely filled with Hebel Adhesive.

b. Ensure holes and chips are completely filled with Hebel Patch. Sand back level.

c. Clean off any remaining Hebel Adhesive runs.

d. The blocks can be sanded when dry to ensure a good surface is presented for surface coatings.

4. Base Rendering and Sealants

a. Mix up Hebel HighBuild render in accordance with the instructions on the bag.

b. Apply alkali- resistant glass fibremesh at corners of wall openings (doors and windows) to minimize corner cracking. The mesh should be embedded into the wet first pass of Hebel HighBuild.

c. Hebel HighBuild should be applied with a hark and trowel with minimal thickness of 6mm.

General purpose, site or prebagged sand and cement renders must not be used on Hebel Autoclaved Aerated Concrete.

d. Render must be stopped at control joints to allow the joint to open/close and function correctly.

e. All control joints and gaps between blockwork and framing around windows must be caulked with an appropriate flexible sealant.

f. Install backing rods approx 10mm from surface.

g. Apply primer to the surfaces.

h. Installed sealants to manufacturer’s specifications.

5. Coatings for External Walls

a. Coatings must comprise a high build acrylic texture coat and finish elastomeric paint membrane.

b. Conventional exterior low build paint must not be used.

c. Allow Hebel HighBuild to fully cure (approx 24 hours depending on weather conditions).

d. Apply primer to the Hebel HighBuild.

e. Apply texture body coat such as Dulux AcraTex. Ensure texture coat stops at control joints.

f. Apply finishing sealants in control joints
g. Apply first finishing paint elastomeric paint membrane
h. Apply second coat of elastomeric paint membrane as required
i. Refer to manfuacturer’s guidline for coating on AAC PowerBlock™work and Hebel® HighBuild™

6.  Internal Linings

a. Plasterboard can be direct fixed to internal Hebel® PowerBlock
™ walls.
b. It is recommended that battens be used behind plasterboard linings on the inside surface of external Hebel  PowerBlock walls.

c. Fibre cement sheet linings can not be direct fixed to Hebel PowerBlocks. Installed fibre
cement sheets linings on battens.

d. Hebel HighBuild render may be directly applied to internal block walls as per pervious instructions.

Floor Panel Notes

1. The ring anchor reinforcement shall be a minimum of N12 grade in accordance with AS1302, unless noted otherwise by the project engineer.
2. Hebel® Mortar should be used as grout for the ring anchor system. A nominal composition of 1 Cement: 4 Sand (5mm maximum coarse aggregate) can also be used.
Minimum compression strength of f’cg= 15MPa at 28 days.
3. Additives to reduce the grout shrinkage shall only be used in accordance with the manufacturer’s instructions.
4. The installer shall support (chair) reinforcement to enable grout to fully surround the reinforcement. Reinforcement shall not be in contact with the panel when grout is placed.
5. Grout shall be rodded to ensure complete filling of notch and groove.

6. The installer shall provide notch and groove at panel joints as per Hebel® standard detail 5.3.5 on page 7.60 in the Hebel® Technical Manual..
7. Ensure notch is cleared of all loose material and reinforcement cleaned
of all foreign material.
8. Lightly pre-wet notch prior to pouring the grout.
9. Panels shall only be cut on-site as indicated on the engineer’s drawings,

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14.0 Construction Details (Typical)

Base of Wall

Fig 14.1 Hebel PowerBlock work on Stiffened Raft Slab Edge Foundation (elevation)

 

Fig 14.2 Hebel PowerBlock work showing infill block to slab rebate (elevation)

 

Fig 14.3 Internal Load Bearing Hebel PowerBlock work on stiffened raft slab foundation (elevation)

 

Fig 14.4 Concrete PowerBlock Sub-Floor Detail (elevation)

 

Fig 14.5 Roof Top to Plate Fixing to Hebel Wall – Strap (elevation) – for vaulted/cathedral roofs

 

Fig 14.6 Roof Top to Plate Fixing to Hebel Wall – Strap (elevation) – for typical trussed roof

 

Fig 14.7  Strap Fixing to Hebel Walls (isometric – typical trussed roof)

 

Fig 14.8  Double Brick Sub-Floor Detail (elevation)

 

Fig 14.9 Ring Beam Internal Non-Loadbearing Wall (elevation)

Top of Wall

Fig 14.10 Internal Hebel Load Bearing Wall and Timber Floor Frame Junction (elevation)

 

Fig 14.11 Truss Spanning Over Non-Load Bearing Hebel Walls (elevation)

 

Fig 14.12 Timber Truss/Joist Fixed to Hebel Walls (elevation)

 

Fig 14.13  Tiled Roof Eve and Hebel Wall Junction (elevation)

 

Fig 14.14  Vaulted Ceiling & Roof Top Plate Fixing To Hebel  Wall (elevation)

Wall Junctions

Fig 14.15  External Wall and Internal Partition Wall Junction  (plan)

 

Fig 14.16  External Corner with Control Joint (plan)

Control Joints

Fig 14.17 Control Joint detail (elevation)

 

Fig 14.18 Typical Bond Beam Control Joint – elevation

 

Fig 14.19 Typical Control Joint – plan 

 

Fig 14.20 Typical Ring Beam Control Joint – elevation

 

Fig 14.21 Hebel PowerBlock work Typical Movement Joint Detail (elevation)

 

Fig 14.22 Hebel PowerBlock work Typical Movement Joint Detail (plan)

 

Fig 14.23 Built-in Column Detail (plan)

 

Fig 14.24 Built-in Column Detail (elevation)

Floors

Fig 14.25 Non-Load Bearing Hebel PowerBlock Wall and Hebel Floor Panel Detail (elevation)

 

Fig 14.26 Loadbearing Hebel PowerBlock Wall and Floor Panel Junction Detail (elevation)

 

Fig 14.27  Loadbearing Hebel PowerBlock Wall and Timber Floor Frame Junction Detail (elevation)

 

Fig 14.28 Timber Floor Support Detail (elevation)

 

Fig 14.29  Hebel Flooring Panels using Ring Anchor Construction on Load Bearing Interior Wall (elevation)

 

Fig 14.30 Ceiling Support Detail A (elevation)

 

Fig 14.31  Ceiling Support Detail B (isometric)

NOTE: Refer to section 7.12 of the Hebel Technical Manual for the full set of Details on the Floor Panel System.

Balcony and Deck

Fig 14.32  Balcony Detail (elevation)

 

Fig 14.33  Balcony Detail (elevation)

 

Fig 14.34  Deck Connection Detail (side elevation)

 

Fig 14.35 Deck Connection Detail (front elevation)

Stairs

Fig 14.36  Stairwell (isometric)

 

Fig 14.37  Stair Tread Set-Out (isometric)

 

Fig 14.38 200mm wide x 50mm thick Hebel PowerBlocks adhered to walls on their ends to provide support for treads (isometric)

Openings

Fig 14.39 Steel Door Frame (Internal or External) to Hebel Wall Fixing (plan)

 

Fig 14.40  Steel Door Frame (Internal or External) to Hebel Wall Fixing (plan)

 

Fig 14.41  Timber Door Frame (External) to Hebel Wall Fixing (plan)

 

Fig 14.42  Timber Door Frame (Internal) to Hebel Wall Fixing (plan)

 

Fig 14.43  Aluminium Window Frame – Window Sill Detail (elevation)

 

Fig 14.44 Aluminium Window Frame – Window Jamb Detail (elevation)

 

Fig 14.45  Aluminium Window Frame – Window Head Detail (elevation)

 

Fig 14.46 Lintel Installation
(a) Elevation

(b) Section

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