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exterior wall cladding

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5 Coating Systems

5.1 Coating /Rendering

The proprietary coating systems consist of polymer-modified cement renders, which must be finished with an acrylic texture and paint. The proprietary coating manufacturer’s instructions and application requirements must be followed at all times. *(Available to download from the QT website) In most cases these coating systems must be applied by an approved applicator. High profile or heavy texture finishes can minimise surface imperfections or glancing light concerns. Light coloured coatings are recommended. Polymer-modified cement renders must not be applied over sealants or control joints.

5.2 Pre – Coating System Inspection

Check all internal and external corners are formed correctly and have good straight lines. Check the first horizontal course, and panels above rooflines have a good clean bottom line. Check weep holes have been installed in the first horizontal course. With a 1.8m spirit level check for variations greater than 3mm in the QT EcoSeries Wall Panels, especially where panels butt together. If variations are found, take the appropriate remedial action eg. rasp to an acceptable level, or re-fix the offending panels. It is important to eliminate large variations, as they may appear under critical or glancing light conditions. If the internal lining has not yet been installed, advise the building supervisor that internal wall lining cannot be installed using nails as the knocking vibrations will transfer through the frame and crack the render coatings (hairline cracking). Hence internal lining must be screwed. After the inspection has been completed, application of the base coat can begin.

5.3 Application of a Polymer Modified Render Base Coat

Trowel an even coat of polymer-modified cement render over the entire QT EcoSeries Wall Panel, embed QT FullMesh into the wet Render, overlapping joints by 100mm minimum. Allow to firm and then screed and or float to a flat and level finish. The purpose of this coat is to even out the substrate and the porosity of the QT EcoSeries Wall Panel. 150mm wide x 300mm long strips of QT 45° Mesh are also required to be set into the base coat at 45° angle across the corner of all windows and door openings into wet render. Do not render or texture over control joints. The above is a generic guide only. Refer to the proprietary coating manufacturer’s instructions for a detailed description of application. Any proprietary coating system specified must meet or exceed the performance criteria of the BCA.

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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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6.0 Design Approach

There are 2 methods of construction – typical and tie-down. Typical is the most common method of building whilst the tie-down method is required for cyclonic or high wind areas (as determined by an engineer). This guide provides information for both building methods.

Important Note

It is the responsibility of the architectural designer and engineering parties to ensure that the information in the Hebel PowerBlocks Design and Installation Guide is appropriate for the intended application. The recommendations of this guide are formulated along the lines of good building practice, but are not intended to be an exhaustive statement of all relevant data. Hebel accepts no responsibility for or in connection with the quality of the recommendations or their suitability for any purpose when installed.

Scope

The Hebel PowerBlocks Design and Installation Guide has been created to provide information for detached residential buildings. The design information in this guide has been condensed from the Hebel Technical Manual and AS3700 Masonry structures. The design basis is AS3700 Masonry structures, Section 12 Simplified design of masonry for small buildings. The footing and slab design is based on AS2870 Residential slabs and footings – Construction.

Refer to Table 6.1 for Building Geometry Limitations.

Design Parameters

The structural design information in this guide is based on the data and assumptions in Table 6.2, 6.3 and 6.4.

Design Sequence

Fig. 6.1 details Hebel recommendations for how to design a Hebel PowerBlock
home.

Fig 6.1:  Flow Chart.

Table 6.1: Buiding Geometry Limitations

2 storeys max
Max. height to underside of eaves 6.0m
Max. height to top of roof ridge 8.5m
Max. building width incl. verandah but not eaves 16.0m
Max. building length 5x width
Max. lower storey wall height 3.0m
Max. upper storey wall height 2.7m
Max. floor load width on external wall 3.0m (6.0m single span floor)
Max. roof load width on external wall 3.0m (6.0m rafter/truss span)
Max. floor load width on internal wall 6.0m

Where the building geometry is outside the above limitations, the designer must refer to the Hebel Technical Manual and AS3700 Sections 1-11.

Table 6.2: Design Parameters

Hebel PowerBlock material properties:
Nominal Dry Density 470 kg/m2
Working Density (S.T.) 611 kg/m2
Working Density (L.T.) 500 kg/m2
Characteristic Compressive Strength, f’m 2.25 MPa
Characteristic Flexural Tensile Strength, f’mt 0.20 MPa
Characteristic Shear Strength, f’ms 0.30 MPa
Characteristic Modulus of Elasticity, EST 1125 MPa
Characteristic Modulus of Elasticity, ELT 562 MPa

Table 6.3 Design Parameters – Permanent and Imposed Actions

Permanent Actions (Dead Loads):
Floor – Superimposed 1.00 kPa
Roof – Tile 0.90 kPa
Roof – Sheet 0.40 kPa
Framed Floor/Deck – Timber 0.50 kPa
Framed Deck – Tile 0.50 kPa
Pergola Roof – Tile 0.80 kPa
Pergola Roof – Sheet 0.32 kPa
Hebel PowerFloor System 0.80 kPa
Hebel Floor Panel System – 250mm 1.90 kPa
Hebel PowerBlock Wall – 250mm, 2700mm (H) 4.60 kN/m
Hebel PowerBlock Wall – 150mm, 2700mm (H) 2.76 kN/m
Imposed Actions (Live Loads):
In accordance with AS 1170. 1:2002
Floor – general 1.50 kPa
Deck 2.00 kPa

Table 6.4  Design Parameters – Wind Actions (General wall areas)

Wind Classification
(AS4055)
Wind Pressure (kPa)
Serviceability, Ws Ultimate, Wu
N1 0.41 0.69
N2 0.41 0.96
N3 0.61 1.50
N4 0.91 2.23
N5 1.33 3.29
N6 1.82 4.44
C1 0.61 2.03
C2 0.91 3.01
C3 1.33 4.44
C4 1.82 5.99

 Image 6.1:  Hebel PowerBlock home

Image 6.2:  Hebel PowerBlock home

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11.0 Fixings for use with Hebel

LIGHT DUTY UP TO 20 kg
Door bell, light fittings, taps
Product Diameter Length Max.Load
Coarse thread screw  10 – 12g  50mm 25kg
Mungo Nylon Plug – MN4 4mm  20mm  2kg
Hilti impact anchor – HPS-1 5mm  30mm  3kg
Mungo Nylon Plug – MN5 5mm  25mm  4kg
Hilti impact anchor – HPS-1 6mm  40mm  4kg
Ramset Ramplug – nylon 5mm  25mm  5kg
Mungo Nylon Plug – MN6 6mm  30mm  6kg
Hilti impact anchor – HPS-1 6mm  50mm  6kg
Mungo Nylon Plug – MN7 7mm  35mm  7kg
Ramset Ramplug – nylon 6mm  30mm  8kg
Fischer – 4 expansion plug 8mm  40mm  8kg
Mungo Nylon Plug – MN8 8mm  40mm  9kg
Ramset Ramplug – nylon 7mm  35mm  12kg
Ramset Ramplug – nylon 8mm  40mm  16kg
Ramset Ramplug – long 6mm  55mm  16kg
Mungo Nylon Plug – MN10 10mm  50mm  20kg
Tox TFS-L fixings 6mm  50mm  20kg
HEAVY DUTY 50kg – 120kg
Grab rails, hose reels
Product Diameter Length Max.Load
Hilti-RE500 Injection adesive 8mm 80mm  50kg
Fischer Turbo plug 8mm 50mm  58kg
Mungo Nylon plug – MN16 16mm 80mm  60kg
Hilti-RE500 Injection adesive 10mm  90mm  70kg
Fischer Turbo plug 10mm  60mm  74kg
Hilti-RE500 Injection adesive 12mm  110mm  90kg
Mungo Nylon plug – MN20 20mm  90mm  100kg
Mungo Nylon Frame anchor 10mm  80mm  110kg
Mungo Nylon Frame anchor 10mm  100mm  110kg
Mungo Nylon Frame anchor 10mm  120mm  110kg
Mungo Nylon Frame anchor 10mm  200mm  110kg
Ramset Injection Mortar 10mm  130mm  120kg
Tox-KD-DV Heavy D Toggle 10mm  100mm  120kg
Tox-KD-DV Heavy D Toggle 10mm  200mm  120kg
Ramset Injection Mortar 8mm  80mm  121kg
Ramset Injection Mortar 10mm  80mm  125kg
Ramset Injection Mortar 12mm  160mm  125kg
MEDIUM DUTY 20-50
Large light fittings
Product Diameter Length Max.Load
 Ramset Ramplug – long 8mm 65mm  22kg
 Ramset Ramplug – nylon 10mm  50mm  25kg
 Fischer 4 expansion plug 10mm  50mm  25kg
 Fischer twist plug GB 8mm  50mm  25kg
 Fischer Universal Frame fix 10mm  50mm  25kg
 Tox Metal claw plug 6mm  32mm  25kg
 Ramset Ramplug – long 10mm  80mm  27kg
 Ramset Ramplug – long 12mm  95mm  28kg
 Powers Zip-it 6mm  30mm  28kg
 Hilti Frame anchor – HRD-U 10mm  80mm  30kg
 Hilti Frame anchor – HRD-U 10mm  100mm  30kg
 Tox-VLF Frame fixings 6mm  70mm  30kg
 Ramset Ramplug – nylon 12mm  60mm  35kg
 Tox Metal claw plug 8mm  60mm  35kg
 Mungo Nylon plug – MN12 12mm  60mm  40kg
 Fischer twist plug GB 10mm  55mm  40kg
 Tox TFS-L fixings  8mm  70mm  40kg
 Tox-VLF Frame fixings  8mm  100mm  40kg
 Fischer Turbo plug  6mm  50mm  44kg
 Mungo Nylon plug – MN14  14mm  79mm  50kg
 Tox TFS-L fixings  10mm  70mm  50kg
 Tox-VLF Frame fixings  10mm  135mm  50kg

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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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