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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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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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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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