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CSR Hebel Installation Guidelines

  By | August 18, 2011 - 2:15 pm | CSR Hebel Power Panels and Blocks Comments Off

General

Before commencing any installation work, clean and tidy up the work area. Mark out the location of the walls.

Wall Framing

Ensure frames are installed plumb and mechanically fixed to the substrate.

All timber framework is to be fabricated and installed to the manufacturer’s specifications and AS1684 or AS1720.1.

Services

Ensure all services are installed within the wall frame and not on the face of the Power Panel.

Deflection Head Track

When the wall locations have been set out, fix the deflection head tracks to the substrate. This is done using suitable fixings (see Section 12.0) at 600mm maximum centres and maximum 100mm from ends. At changes in wall directions, ensure deflection head track is mitred with no gaps at the corners. Seal all butt joints with polyurethane sealant.

Hebel Mortar

Mortar is placed on the DPC and should only be run out roughly 3 panels (1800mm) ahead of panel installation. The mortar bed fills the gap at the base. Generally, the mortar is 10mm thick and shall extend the full width of the panel. Mixing of the mortar should be done in  accordance with the instructions on the bag.

Wall Brackets

Screw fix the wall bracket to the top and bottom plates of the wall frame and to the Power Panel at 600  centres. Locate within 50mm of the centre width of each panel using fixings specified in Section 12.10.

Top Hats

Top hats should be cut to size before securing them to timber studs. At control joints the top hats should be discontinuous. For number, location, spacing and fixing of top hats, refer to the project specifications. The project classification (Torrens or Strata) will determine the future external loading parameters of the panels and associated top hat and fixing arrangement required.

Hebel Power Panel 

The panels can be cut on-site using a circular saw equipped with diamond tipped cutting blade (for panel cutting limitations refer to Section 9.0). All the loose AAC particles should be  brushed off  the panel with a  rough broom.  Steel  reinforcement that is exposed during
cutting must be coated with a liberal application of corrosion protection coating (see Section 12.0). Any minor damage and chips to the panels must be repaired using Hebel Patch.

Use packers at  the base to maintain the gap and ensure gap is  full of mortar  (if specified).
The preferred method of fixing should be to screw through the top hat/bracket into the panel. Fix  the panel to the  deflection head  (if specified).  For following panels, apply Hebel
Adhesive to the vertical edge and install the next panel. Repeat the installation process until the wall is complete.

Hebel Adhesive

Hebel Adhesive is applied to the panel with a 75mm Hebel notched trowel. When the panels are pushed together the joints are to be 2-3mm thick. Sufficient pressure must be applied to the panels when gluing to ensure the adhesive is fully bedded across the joint. Scrape off any excess adhesive protruding from the joints and fill any gaps. Adhesive is to be mixed to the proportions and consistency as per the instructions on the bag.

CSR Bradford Insulation

Installation of CSR Bradford insulation should be completed in accordance with  manufacturer’s  handling  and  installation  guidelines.  The insulation  provided   should
completely fill the space between the stud framing and form a continuing barrier. If there is any gap in the insulation the acoustic performance of the system may be adversely affected.

Gyprock Plasterboard

Plasterboard sheets must be cut to fit neatly and should not be forced into position. The plasterboard is to extend the full height of the wall frame, with gaps at top and bottom for the specified sealant.
Plasterboard is fixed directly to the stud framework in accordance with the Gyprock Plasterboard Residential Installation Guide, NºGYP547.

 Sealants

All movement joints and other gaps should be sealed off and finished neatly with fire and acoustic rated sealants. Installation of sealants must be carried out in accordance with the
manufacturer’s specifications.

Installation of Electrical, Plumbing and Other Services

Installation of services into walls should be carried out at an appropriate construction sequence. This will allow easy access to cavities and wall frames, where services can be easily installed and neatly hidden.
CSR Hebel suggests installing the plumbing and cabling after the panels have been installed. The builder or project manager should confirm appropriate construction sequence for services on a project-by-project basis.

Fasteners & Fixings

All fixings and fasteners should be installed in accordance with the manufacturer’s specifications.Find Out More

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CSR Hebel Panel Handling, Delivery & Storage

  By | August 18, 2011 - 12:14 pm | CSR Hebel Power Panels and Blocks Comments Off

Manual Handling

CSR Hebel recommends using a trolley or other mechanical apparatus to move the panels around the work site. Manual handling where people physically move a panel, should be kept to a minimum, with the weight being supported by an individual kept as small as possible. Any concerns regarding the weight to be handled should be discussed with the panel installation contractor.

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

  • Use mechanical aids, such as trolleys, forklifts, cranes and levers, or team lifting to move panels.
  • 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.
  • Train employees in good lifting techniques to minimise the risk of injury.

Health, Safety & Personal Protective Equipment (PPE)

CSR 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 CSR Hebel AAC and other concrete 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 appropriate CSR Hebel Material Safety Data Sheet (MSDS). For further information, contact CSR Hebel or visit the website.

Cutting

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

Refer to the appropriate CSR Hebel MSDS. For further information, contact CSR Hebel or visit the website.

Reinforcement exposed during cutting is to be coated with a liberal application of CSR Hebel anti-corrosion coating agent.

Trolley Assisted Handling

CSR Hebel has developed a trolley to allow easier and safer handling of Hebel PowerPanel on-site (refer Image 14.1). There is a range of trolleys to suit panels from 1.2m to 3.9m in length.

Guidelines for handling Hebel PowerPanel using the Hebel PowerPanel Trolley or panel lifters are detailed in Technical Bulletin, CSR Hebel PowerPanel Handling & Installation Guidelines, NºHTB791.

Hebel PowerPanel Trolley for 2700mm panels       Typical Personal Protective Equipment

Delivery & Storage

Unloading Panels

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

Note: Secondary handling increases the risk of panel damage. The repair of damage sustained during lifting and moving is the responsibility of the lifter. Where damage is excessive, panels must be replaced.

Storage

All materials must be kept dry and preferably stored undercover. Care should be taken to avoid sagging or damage to ends, edges and surfaces.

All CSR Hebel products must be stacked on edge and properly supported off the ground, on a level platform. Panel bundles can be stacked two high. The project engineer should be consulted as to the adequacy of the structure to support the stacked bundles. Each bundle contains 10 panels (refer Detail 15.1). Where bundles are stacked two high, the supporting cleats must be vertically aligned, to ensure minimal bending of the lower panels. Refer to Detail 15.2.

If Hebel PowerPanel is stored outside, it must be stored off the ground and protected from the weather. Only single bundles positioned on the ground can be opened. To provide a level surface, we recommend placing temporary joists beneath the supporting cleats.

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CSR Hebel Construction Detail – 75mm Hebel Intertenancy 002

  By | August 18, 2011 - 9:27 am | CSR Hebel Power Panels and Blocks Comments Off

1 Overview of 75mm Hebel Intertenancy 002 System

* NOT SUITABLE FOR STEEL FRAME CONSTRUCTION. NOT DEEMED DIS CONTINUOUS CONSTRUCTION.

Note: Detailing of elements, such as flashings, gutters, capping, roofing, etc. shown in this section are for indicative purposes only.

Vertical Cross Section of 75mm Hebel Intertenancy 002

*Not suitable for steel frame construction. Not deemed discontinuous construction.

2 Construction Details for 75mm Hebel Intertenancy 002

*Not suitable for steel frame construction. Not deemed discontinuous construction.

Junction Details for 75mm Hebel Intertenancy 002

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CSR Hebel Appendix A & Appendix B

  By | August 18, 2011 - 5:52 am | CSR Hebel Power Panels and Blocks Comments Off

A1 – Hebel PowerPanel Material Properties

Hebel PowerPanel Physical Properties
1) Hebel PowerPanel profile and nominal dimensions are shown in Section 12.0.
2) Panel reinforcement is a single layer of steel mesh with 4 longitudinal wires of 5mm diameter.
3) Nominal dry density of AAC = 510 kg/m3.
4) Average working density of AAC = 663 kg/m3 at 30% moisture content.
5) Average service life density of AAC = 561 kg/m3 at 10% moisture content.
6) For custom PowerPanel, average working density = 707 kg/m3 at 30% moisture content.

PowerPanel Strength Properties
1) Characteristic Compressive Strength or AAC, f ’m = 2.8 MPa.
2) Average Compressive Strength of AAC = 4.0 MPa.
3) Characteristic Modulus of Rupture, f ’ut = 0.60 MPa.

PowerPanel Acoustic Properties
1) Panel only with no plasterboard or other lining Rw= 36dB, Rw+Ctr = 33dB (refer to acoustic test ATF-676).

PowerPanel Thermal Properties
1) R-Value of PowerPanel with no plasterboard or other lining = 0.51 m2 .K/W (4% moisture content).

Fire Hazard Indices
CSR Hebel  AAC products have the following early fire hazard indices, determined in accordance with AS1530.3:1990:

Fire Resistance Level (FRL)
For fire performance characteristics of Hebel low rise party wall systems, refer to Section 8.0 of this publication.

A2 Assessment Methods

Test Reports
Tests performed on 75mm Hebel Intertenancy 001 and 002 have been done in accordance with relevant Australian Standards at the time of testing.

Fire test reports and assessments have been issued by Warrington Fire Research (Aust) Pty Ltd.

Test reports, assessments and opinions quoted in this design guide are available on request from CSR Hebel.

Sound Insulation Estimates
Acoustic consultants often use computer models to determine sound transmission estimates for specific wall system configurations. These are known as ‘Acoustic Assessments’ or ‘Acoustic Opinions’. The computer model predicts the Rw performance expected from a laboratory test on the system. Acoustic opinions have been issued by PKA.
Acoustic Consulting Pty Ltd All acoustic opinions quoted in this design guide are available on request from CSR Hebel.

Appendix B

B1 Architectural Specification

This specification should be adopted as a guide only, and shall be superseded by the contract specifications of the project.

* Insert or select appropriate specifications.

Scope
The contractor shall furnish all material and equipment required to satisfactorily complete the installation and jointing of the specified Hebel PartyWall system where indicated in the contract specification and/or on the layout drawings.

Materials
All AAC material shall be Hebel PowerPanel as manufactured by CSR Hebel.

All accompanying fixings shall be as per the current Hebel Low Rise Multi-Residential Party Walls Design & Installation Guide, NºHBLA228 LRPW and/or the appropriate project consultant’s specifications.

All lining materials shall be Gyprock plasterboard or Cemintel Fibre Cement sheet as manufactured and supplied by CSR Building Products (or products of equivalent or better performance). Plasterboard shall be manufactured to meet the dimensional requirements of AS/NZS2588 ‘Gypsum Plasterboard’.

Steel frame components shall be those manufactured by Rondo Building Services Pty Ltd (or products of equivalent or better performance).

All infill material shall be CSR Bradford infill as manufactured and/or supplied by CSR Bradford (or products of equivalent or better performance).

Wall System
The contractor shall supply and install
*75mm Hebel Intertenancy 001, Option ……… or
*75mm Hebel Intertenancy 002, Option……… in accordance with the current Hebel PartyWall Design & Installation Guide, NºHBLA228 LRPW, and shall satisfy the following performance criteria.

The wall shall have a Fire Resistance Level *FRL ……/……/…… in accordance with the requirements of AS1530.4.

Installation shall be carried out to the level specified for a field acoustic performance of *D
ntw /R‘ w  …………… using cavity infill of *Bradford………………… (or products of equivalent or better performance).

Lining Boards
The stud frame on each side or the PartyWall shall be lined with one layer of *…………mm Gyprock *……………… plasterboard, or one layer of *…………mm Cemintel *……………… fibre cement sheet.
All layers shall be fixed and caulked as specified for the relevant system in the Gyprock Plasterboard Installation Manual, NºGYP547, other relevant CSR technical literature, and Rondo Building Services literature or appropriate steel frame manufacturer’s literature.

Plasterboard Levels of Finish
All framing, plasterboard lining, jointing and finishing shall be carried out to *Level ………Level of Finish, in accordance with Gyprock Plasterboard Installation Manual, NºGYP547 and/or AS/NZS2589.1 ‘Gypsum Linings in Residential and Light Commercial Construction – Application and Finishing’.

Caulking
Provide a * one or two sealant system in accordance with the sealant manufacturer’s requirements. The sealant system shall meet or exceed the fire resistance level (FRL) rating of the Hebel PartyWall system in which it is used.

In fire rated systems where caulking is indicated, use *……………… fire rated polyurethane sealant with non fire-rated backing rod, installed in accordance with the manufacturer’s recommendations or use *……………… acoustic rated polyurethane sealant with fire-rated backing rod installed in accordance with the manufacturer’s recommendations.

In non fire-rated or fire-rated wet areas where caulking is indicated, use fire rated *……………… polyurethane sealant installed in accordance with the manufacturer’s recommendations.

Important
Any variation or substitution of materials or assembly requirements, or compromise in assembly may result in failure under critical conditions.

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