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8 Product Information

8.1 Storage and Handling

Care should be exercised in handling the QT EcoSeries Wall Panels to avoid any damage to edges, ends and faces. Panels must be stacked flat, off the ground and supported on a level platform. Plastic Shrinkwrap applied to pallets of panels for transportation from the factory, must be removed at the destination (i.e. distributors warehouse or direct to site) to allow panel to continue drying and equalise with local humidity. The panels must be kept dry at all times by storing under cover, or providing weatherproof covers to the stack. Panels must be dry prior to fixing. Intermittent weather exposure is not detrimental to the panel. However if QT EcoSeries Wall Panels become wet, allow thorough drying before fixing. Drying shrinkage may occur if the QT EcoSeries Wall Panels are not allowed to dry sufficiently. The proprietary Coating System must be applied and completed within 1 month from the date of installation of the QT EcoSeries Wall Panels.

QT EcoSeries Wall Panels and cement based renders, will release their salts and/or fines if saturated; this condition is know as efflorescence. In order to prevent efflorescence the cement products must be sealed to prevent the ingress of moisture and/or installed with careful attention to the weather-tightness details to prevent the ingress of wind driven rain, gutter overflow or moisture tracking along a surface with capillary action. The water that has permeated through the panel and render will collect and dissolve any salts and/or fines that are then released through hairline cracking in the render which are caused by hydrostatic pressure build up. The dissolved salts and/or fines will crystallise on the external surface. Should efflorescence occur, it is essential that the moisture source be eliminated and any hairline cracking repaired to maintain weathertightness. Refer to coating manufacturer for suitable surface repair techniques.

Panels must always be carried on edge. Any minor damage should be repaired with joint compounds or polyurethane foam. Fixings and other accessories must be stored so that they are kept clean, dry and undamaged. All components must be used within the designated shelf life. Any damage to Clips and Channel may affect the integrity or performance of the wall system. Panel may be cut with an electric circular saw 60 pt tungsten tip blade, diamond blade or handsaw. Panels are best shaped with the use of an electric plane or a handrasping tool. Holes or services may be formed with the use of an electric fretsaw or drill. When power tools are used for cutting, grinding or forming holes in the panels, appropriate safety measures as set out under the heading of Health and Safety must be observed. All materials that are susceptible to deterioration due to plastics migration or alkalinity of cement base products must be protected (check with product manufacturer).

8.2 Quality Policy

QT Systems Pty Ltd is dedicated to delivering quality building systems for internal and external use on residential and commercial projects. QT Systems Pty Ltd is committed to ensuring that its Conpolcrete building products provide the highest standards and consistency by meeting the requirements of customers and regulatory authorities. This objective is met through the implementation of a Quality System, based upon the requirements of an internationally recognised quality standard: AS/NZS ISO 9001:2000. Continued testing and independent scrutiny will ensure QT Systems Pty Ltd continues to offer an eco-friendly alternative construction material that consistently provides outstanding performance.

8.3 Maintenance

Annual inspection of the exterior walls must be made to ensure they remain in a weatherproof condition. Checks must be made of the exterior coating system, sealants, flashings, control joints and any water-proofing systems. Should any repairs be required, seek remedial advice from the manufacturer. If the project is still under the statutory warranty period contact the appropriate body, or check with your insurer.

8.4 Limitations of the QT EcoSeries Wall Panel System

QT EcoSeries Wall Panels are not designed to provide bracing for the building. The internal linings or other specifically designed systems must provide external wall bracing.

QT EcoSeries Wall Panels are not suitable to be used for chimneys and flues.

QT EcoSeries Wall Panels must not come in contact with the ground for extended periods of time. The panel must not be used for retaining.

This Technical Manual is limited to residential construction, for other applications contact your QT Distributor.

Designers must check that the details in this Technical Manual meet their own specific design requirements. For use outside the scope of this Technical Manual, specific design may be necessary. The Architect, Designer, Engineer, Specifier and Builder, are responsible for specific design and should ensure compliance with the BCA.

8.5 Product Support

Installers are registered trades people, equipped to install the panel and its complementary accessories. These installers, acting as independent contractors, should be industry licensed trades people such as carpenters or dry wall installers who are familiar with the QT EcoSeries Wall Panel system and components. The authorized agent or appointed licensee shall supply all QT EcoSeries Wall Panel system components directly to the contracting or sub-contracting party. We recommend you seek advice from all manufacturers or suppliers, regarding correct installation and maintenance requirements associated with their products. Failure to comply with specification requirements, which may compromise the exterior coating, sealants, flashing, weatherproofing and waterproofing, will render any manufacturers warranty void.

QT Systems Pty Ltd regularly updates its literature to keep up with system and product developments, changing trends in design, and therefore reserves the right, to revise and change its technical information without notice.

8.6 Health and Safety

As with all cement based composite products, they contain crystalline silica. Breathing in
fine silica dust is hazardous and may result in bronchitis, silicosis (lung fibrosis) and lung cancer. Do not breathe dust, always contain dust during clean up and disposal i.e. place dust in a sealed bag. Safe working practice is to avoid contact with skin, eyes and lungs, e.g. full-length clothing including boots, P1 or P2 dust mask, and safety goggles to AS 1337. (Wash worn clothing regularly, each day). We recommend that you always seek advice for recommended handling, health and safety requirements for products or components by other suppliers and manufacturers. Consult your local Work Place Health and Safety Officer for specific advice. Also see Material Safety Data Sheets for specific products.

8.7 Components & Accessories

8.8 General Warranty

New Product 15 year Warranty.

This warranty cover limits any cost or liability arising from the supply of defective Conpolcrete products, excluding third party manufactured accessories and components. Liability is limited to replacement and or repair of any defect solely attributable to defective Conpolcrete manufactured products that do not meet the manufacturers standards. No liability is assumed or implied for project supervision or defects caused by improper installation of the system.

8.9 Disclaimer

QT Systems Pty Ltd provides the information in this manual in good faith and to the best of its knowledge the information is correct and covers most situations where its products may be used. However, it is acknowledged that not every possible application of QT products could be covered within this manual therefore specific design and detailing, must be undertaken by the designer. The Specifier, Architect, Designer and Engineer for the project are responsible to ensure that the information and details in this manual are suitable for any intended application or specific design.

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1 Series Corners

Internal Corners
QT FullMesh
(AS-3.1.B)

Panel to Wall Sheet Junction
(AS-3.6.B)

External Corners
Corner Bead
(AS-3.2.C)

 

Horizontal Expansion Joint
(AS-3.3.C)

Note
All panel fixings to be 10g x 75mm class 3 screws or 75 x 3.15 ø or 3.75 ø class 3 ring shank nails with QT Buttons at 225mm centres as per technical manual section 2. Batten fixings should be class 3 and as section 2 of the technical manual.

Vertical Expansion Joint
(AS-3.4.B)

Panel to Brick Junction
(AS-3.7.B)

Note
All panel fixings to be 10g x 75mm class 3 screws or 75 x 3.15 ø or 3.75 ø class 3 ring shank nails with QT Buttons at 225mm centres as per technical manual section 2. Batten fixings should be class 3 and as section 2 of the technical manual.

Panel Upper Storey to Brick Lower Storey Junction
(AS-3.8.C)

Note
All panel fixings to be 10g x 75mm class 3 screws or 75 x 3.15 ø or 3.75 ø class 3 ring shank nails with QT Buttons at 225mm centres as per technical manual section 2. Batten fixings should be class 3 and as section 2 of the technical manual.

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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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10.0 Tools & Equipment for Construction

Hebel PowerBlocks can be laid using construction tools/equipment.

String Line – A string line is required to accurately set out and lay Hebel PowerBlock Walls.

Brick/Blocklaying Profiles – used to gauge the block course are being laid level.

Mixing Bucket – a minimum 20 litre bucket is required for mixing Hebel Mortar, Hebel Adhesive and Hebel HighBuild render.

Electric Drill – an electric drill is required to mix the Hebel Mortar, Hebel Adhesive and Hebel HighBuild render. It is also used to drill clearance holes in the blocks so they can be placed over the tied down rods where required.

Stirrer – fitted to the electric drill, the stirrer is used to mix the Hebel Mortar, Hebel Adhesive and Hebel HighBuild render inside the mixing bucket.

Notched Trowel – the notched trowel is used to apply the Hebel Adhesive to the Hebel surfaces. The width of the trowel must match the block thickness to ensure the adhesive is applied with full and even coverage.

Rubber Mallet – a rubber mallet is required to ‘tap’ the Hebel PowerBlocks onto the adhesive and into place.

Spirit Level – required to install the blocks level and plumb.

Hand Saw – a Hebel handsaw can be used to cut Hebel PowerBlocks to length and height.

Powered Bandsaw – a bandsaw is ideal for cutting Hebel PowerBlocks. (perfect when there are many site cuts to be performed).

Hebel Square – a purpose built square is available for use when marking and cutting Hebel PowerBlocks.

Steel, Plastic and Timber Trowels – these trowels may be required for the installation of the Highbuild render and texture coatings.

Sanding Float – used to even out inconsistencies in the Hebel PowerBlock Wall in preparation for render/texture coats.

Hebel Hand Router – may be used to chase services into solid Hebel walls.

Circular Saw – (fitted with a diamond blade) may be used to chase services into solid Hebel walls.

Electric Router – may be used to chase services into solid Hebel walls.

Crane – may be required to lift large Hebel Lintels and Hebel custom floor panels.

Lifting Grabs – required for use in conjunction with crane for lifting Hebel lintels and custom floor panels.

Scaffold – Scaffold is required when building block walls. The amount of scaffold depends on the height of the walls.

Sealant Gun – required to fill the control joints in the Hebel PowerBlock Walls.

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12.0 PowerBlock Handling

Manual Handling

To minimise the possibility of manual handling injuries, Hebel suggests the following:

  • Use mechanical aids, such as trolleys, forklifts, cranes and levers, or team lifting to move Hebel.
  • Keep the work place clean to reduce the risk of slips, trips and falls, which can cause injury.
  • Plan the sequence of installation to minimise panel movements and avoid awkward lifts.
  • Good lifting techniques to be adopted to minimise the risk of injury.

Mechanically Assisted Handling

Moving and handling Hebel Floor Panels and Hebel Lintels should be done using mechanical aids such us forklifts, cranes and special panel lifting trolleys. Different panel lift attachments are available for installing panels. For purchasing or hire of these devices please contact CSR Panel Systems.

Health, Safety & Personal Protective Equipment (PPE)

Hebel AAC products are cement-based, which may irritate the skin, resulting in itching and occasionally a red rash. The wearing of gloves and suitable clothing to reduce abrasion and irritation of the skin is recommended when handling Hebel AAC products.

Approved respirators (AS/NZS1715 and AS/NZ1716) and eye protection (AS1336) should be worn at all times when cutting and chasing. Refer to the Hebel Material Safety Data Sheets (MSDS).

Cutting

The use of power tools when cutting masonry products may cause dust, which contains respirable crystalline silica, with the potential to cause bronchitis, silicious and lung cancer after repeated and prolonged exposure. When using power or hand tools, on Hebel products, wear a P1 or P2 respirator and eye protection. When cutting, routing or chasing Hebel products with power tools, use dust extraction equipment and wear appropriate hearing protection. Refer to the appropriate Hebel MSDS.

Reinforcement exposed during cutting is to be coated with a liberal application of Hebel corrosion protection paint.

Fig. 12.1 Standard personal protection equipment.

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13.0 Delivery & Storage

PowerBlock Delivery

PowerBlock pallets should be unloaded and moved with only approved lifting devices. Before use, the lifting devices should be checked for the required lifting tags. PowerBlock pallets should be unloaded and stored as close to the intended installation area as possible. This will increase work efficiency and minimise the need for secondary lifting.

It is good practice to inspect the delivery for damaged blocks. Unnecessary handling will increase the risk of damage to the Hebel PowerBlocks. Care should be taken when cutting the packaging straps, blocks may come away and cause injury or become damaged.

TIP – When a block is damaged it may be possible to cut away the damaged section and use the remaining portion in the wall.

Storage

All materials must be kept dry and preferably stored undercover. Hebel PowerBlocks should be left on their pallet until they are required. Place the pallet on a level and stable surface. The project engineer should be consulted as to the adequacy of the structure to support Hebel PowerBlocks if they are not stored directly on the ground or concrete slab.

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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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