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panel wall system

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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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3.0 Energy Efficiency

Table 3.1 shows a number of different external wall configurations and identifies which satisfy the BCA requirement for Climate Zones 1 to 8. Table 3.2 lists the component R-Values used as a basis for Table 3.1. For more information on Hebel and energy efficiency refer to Section 3 and Appendix C and D of the Hebel Technical Manual.

Table 3.1:  BCA Energy Efficiency Compliance
Wall Configuration Satisfies BCA Requirements
Climate Zone: 1* 2* 3* 4 5 6 7 8
Class 1 & Class 10a Minimum R-Value: 1.4 1.4 1.4 2.2 1.9 2.2 2.4 3.3
1. 250mm Block Only Y Y Y N Y N N N
2. 250mm Block + 25mm Cavity Y Y Y Y Y Y N N
3. 250mm Block + 25mm Cavity + Sarking Y Y Y Y Y Y Y N
4. 250mm Block + 25mm Cavity + 75mm PowerPane Y Y Y Y Y Y Y N
5. 250mm Block + 40mm Cavity + R1.0 Insulation Y Y Y Y Y Y Y N
6. 250mm Block + 25mm Cavity + Double Sided RFL + 25mm Cavity Y Y Y Y Y Y Y Y
7. 250mm Block + 90mm Cavity + R2.0 Insulation Y Y Y Y Y Y Y Y

*Note: For elevated ground floor slabs an R-Value of 1.9 is required

Table 3.2:  Wall Element R-Value
System Number Construction Overall Thickness R-Value Rw Rw+Ctr
401 8mm Render in Texture Coat and Paint250mm Hebel PowerBlock 10mm Gyprock 268 mm 2.1 48 43
402 8mm Render in Texture Coat and Paint250mm Hebel PowerBlock 28mm furring channels @600mm centres 10mm Gyprock 296mm 2.3 51 43
403 8mm Render in Texture Coat and Paint250mm Hebel PowerBlock 28mm furring channels @600mm centres Non reflective (normal sarking) 10mm Gyprock 296mm 2.3 51 43
404 8mm Render in Texture Coat and Paint250mm Hebel PowerBlock 28mm furring channels @600mm centres Reflective foil 10mm Gyprock 296mm 2.6 51 43
405 8mm Render in Texture Coat and Paint250mm Hebel PowerBlock 28mm furring channels @600mm centres with 50mm 11kg – Bradford Glasswool Non reflective (sarking) 10mm Gyprock 296mm 3.1 53 44
406 8mm Render in Texture Coat and Paint250mm Hebel PowerBlock 8mm Render in Texture Coat and Paint 216mm 2.1 48 43

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4.0 Fire

Hebel AAC has a BCA Group Number 1. Hebel PowerBlock walls satisfy BCA 2008 Vol.2 Clause 3.7.1.5 (a) (iii) masonry construction and therefore suitable for boundary wall construction on a Class 1 building.

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5.0 Acoustic

Table 5.1 provides acoustic performance levels for PowerBlock walls. For alternatives and composite wall construction, Table 3.2 are acoustic performance for PowerBlock systems.

Table 5.1:  Acoustic Performance

PowerBlock Thickness Rw Rw+ Ctr
100 38 35
150 42 40
250 45 42

Values for PowerBlock only, no linings.

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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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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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Appendix A – Carpet Installation

Panel Surface Preparation

Sweep the floor surface to remove debris and loose particles. Expose all surface blemishes such as chips, cracks, gaps, ridges or the like. Fill all unacceptable locations with an appropriate and compatible patching compound such as Hebel® Patch or levelling compound as required. Ensure panels are then dry.

Carpet Smooth Edge Installation

Installation of Carpet Smooth Edge (Gripper) is to be in accordance with AS/NZS 2455.1:1995.

Installation of carpet gripper prior to laying carpet requires the use of specifically selected nails or course threaded screws. Standard fixings supplied with the carpet gripper are not suitable for fixing to Hebel® PowerFloor™ panels. Carpet gripper strips are available without factory supplied nails. For carpet gripper installation near the panel edge, only glue is recommended. If relying on glue only, the carpet can not be stretched until the glue is set after approximately 24 hours.

Table A.1 – Carpet Smooth Edge Fixings

Fixing Type Description Application
Method
Installation Notes
Twist Nails 51mm dome
head twist nail
Coil Nail Gun
(Refer to Fig A.1)
The head of the twist nail
should finish flush with
the surface of the gripper
strip
Screws Type 17 point
– course thread
No. 8g x 50mm
– Countersinking
screw
Makita 6834
Auto Feed
Screwdriver
(Refer to Fig A.2)
The head of the twist nail
should finish flush with
the surface of the carpet
gripper strip
Screws Type 17 pointTrimhead deck
Screw.
4.2 x 50mm
4.2 x 65mm
Quickdrive auto feed The head of the screw
should be flush with the
smooth edge

Underlay Installation

Minimum medium duty underlay is to be used. No other special requirements.

Carpet Installation

As per carpet manufacturer’s guidelines.
No other special requirements.

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