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external wall cladding materials

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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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8.0 System Components

Products

Hebel stocks many of the products and materials required to construct your Hebel home.

Product Description Product Description
  Hebel Thermoblocks

50mm – 300mm (25mm
increments)

Hebel Adhesive
20 kg bag

Used for gluing
the blocks together
at vertical and
horizontal joints

 

Sill blocks

600x200x50mm
thick or 100mm
thick, 30º slope

 

PowerFloor Panels

1800mm x 600mm x 75mm

Hebel Mortar 20 kg bag

Used as thick bed
mortar base to
provide a level
base for the
first course

  Custom PowerFloor
Panels

150mm – 250mm x 600mm
by up to 6m

Hebel Lintels

To suit openings
up to 5m

Hebel HighBuild
render 20kg bag

Used as a preparation
coat to level surface
providing an even
true surface

 

Stair treads

300mm x 175mm x 1m or 1.2m

Control joint tie

Used at every
third course in
control joints

Hebel Patch
10kg bag

Used to prepare
minor chips or
damage to blocks

 

Sliding joint tie

Fixed to RHS/SHS
column every
second course

 

Corrosion Protection Paint

To coat exposed
reinforcement during cutting

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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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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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15.0 Construction Details – Tie-down

Required only if specified by design /project engineer

Fig 15.1:  Strip Footing, Double Brick Sub-Floor

 

Fig 15.2:  Strip Footing, Concrete PowerBlock Sub-Floor

Tie down rods/engineering restraints must be embedded into the footing and pass up through the sub floor and into the Hebel PowerBlock work.

Table 15.1 Top-Plate & Hold-Down selection

Wind
Classification
Top Plate & Hold-Down
Tile Roof Sheet Roof
N1 A / B / C B / C
N2 A / B / C D / F
N3 D / F D / F
N4 D / F D / F
N5 E / G E / G
N6 E / G E / G
C1 D / F D / F
C2 E / G E / G
C3 E / G E / G
C4 G G
Legend
A 90×45 F7 timber top plate / 700mm deep strap @ 1200mm ctrs.
B 90×45 F17 timber top plate / 1700mm deep strap @ 2400mm ctrs
C 90×45 F17 timber top plate / Ф12mm rod @ 2400mm ctrs
D 90×45 F17 timber top plate / Ф12mm rod @ 1200mm ctrs.
E 90×45 F17 timber top plate / Ф12mm rod @ 900mm ctrs.
F 100x50x3.0 RHS top plate / Ф12mm rod @ 2400mm ctrs
G 100x50x3.0 RHS top plate / Ф12mm rod @ 1200mm ctrs.

 

Fig 15.3 Hold Down Detail for Reinforced Bracing Walls

Table 15.2 provides ultimate racking capacities of reinforced 150mm and 250mm Hebel PowerBlock walls. The reinforcement is N12 bar or 12mm threaded rod at nominal 1000mm centres. The reinforcement must be tied to the footings and wall top plate through the bond beam. Walls resisting racking forces should be evenly distributed within a house and spaced at a maximum of 8.0m. Ceiling and floor diaphragms must be adequately tied to walls to ensure transfer of forces through to the footings.For more information about bracing, refer to Section 6.11 of the Hebel Technical Manual.

Fig 15.4 Roof Top to Plate Fixing to Hebel Wall – Strap (elevation)

Top Plate Hold-Down

Two tie-down methods are provided in this design guide.

1. Strap – 30×0.8mm cut into inside face of external wall min. 700mm deep.
2. 12mm threaded rod continuous from footing through bond beam to top plate.

Fig 15.5 Roof Top Plate Fixing to Hebel Wall-Tie-Down Rod (elevation)

Three top plates options are provided in this design guide:

1. 90×45 F7 timber
2. 90×45 F17 timber
3. 100x50x3.0 RHS

The type of hold-down method and spacing depends on the top plate, roof type/span, and wind classification. Refer to Table 15.1 for specifications. For high wind areas, the bracing design is likely to require tie-down rods which will drive that as the hold-down method.

Table  15.2 Reinforced Wall – N12 Bars at Nom. 1000mm CTRS

Wall Length
(mm)
Min. No. of
N12 Bars
Ultimate Racking Capacity (kN)
150mm PowerBlock 250mm PowerBlock
900 2 5 6
1200 2 8 8
1800 3 16 18
2400 3 24 25
3000 4 36 38
3600 5 45 46
4800 6 54 56
6000 7 63 66

Base of Wall

Fig 15.6 Hebel PowerBlock work on Stiffened Raft Slab Edge Foundation (elevation)

 

Fig 15.7  Concrete PowerBlock Sub-Floor Detail (elevation)

 

Fig 15.8  Double Brick Sub-Floor Detail (elevation)

 

Fig 15.9 Ring Beam Internal Non-Loadbearing Wall (elevation) (No tie down – as specified by design engineer)

 

Top of Wall

Fig 15.10 Roof Top Plate Fixing to Hebel Wall – Tie-Down Rod ( elevation)

 

Fig 15.11 Internal Hebel Load Bearing Wall and Timber Floor Frame Junction (elevation)

Wall Junctions

Fig 15.12  External Wall and Internal Partition Wall Junction  (plan)

 

Fig 15.13  External Corner with Control Joint (plan)

Control Joints

Fig 15.14 Control Joint detail (elevation)

 

Fig 15.15 Typical Bond Beam Control Joint – elevation (Location where no tie down required – as specified by engineer)

 

Fig 15.16 Typical Ring Beam Control Joint – elevation (Location where no tie down required – as specified by engineer)

 

Fig 15.17 Typical Control Joint – plan

 

Fig 15.18 Hebel PowerBlock work Typical Movement Joint Detail (elevation)

 

Fig 15.19 Hebel PowerBlock work Typical Movement Joint Detail (plan)

 

Fig 15.20 Built-in Column Detail (plan)

 

Fig 15.21 Built-in Column Detail (elevation)

 

PLEASE NOTE:
For all other design details (eg. door, window, floor panels) please follow the previous construction details in Section 14.0)

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