The fire resistance level (FRL) rating performance of the Hebel PartyWall system detailed in this guide have been derived from Warrington Fire Research assessment WFRA – 45771.3, WFRA – 45772.1 and Warrington Fire Research, fire resistance test report, WFRA – 41154.2.

This design guide has no recommendations for penetrations through the PartyWall system. CSR Hebel recommends contacting the appropriate consultant for design and detailing advice.

System Variations

Certain variations to the Hebel PartyWall installation will not affect the fire-resistance levels listed in Tables 6.1 and 6.2. However these variations need to be approved by the project fire consultant or project certifier. The possible variations to the systems include:
1) Changing the type of insulation between polyester, glasswool and rockwool;
2) Putting the insulation on both sides of the PowerPanel;
3) The reduction of a cavity between the wall frame and the Hebel  PowerPanel/ plaster board down to 10mm for 75mm Hebel Intertenancy 001.

Structural Provisions

Structural Performance

The Hebel PartyWall system can be either a loadbearing or non-loadbearing wall. The Hebel PowerPanel within the wall system is non-loadbearing with the exception of self weight.

Construction Loadings

During construction, the Hebel PowerPanel could be subject to wind loading. The builder shall provide the necessary temporary bracing of the panel until both structural frames are
installed.

Note: The screw connections may not be adequate to stabilise the panel against construction loadings.

Cutting of Hebel PowerPanel

The standard Hebel PowerPanel can be reduced in length by cutting 150mm maximum from each end, and to a minimum width of 270mm. All exposed steel reinforcement shall be liberally coated with the Fentak anti-corrosion coating available through CSR Hebel.

Wall Frame

The wall framing presented in this Design Guide for various wall systems are nominated for the acoustic and fire performance values. It is the designer’s responsibility to determine an  appropriate wall  framing  system to  satisfy  structural  adequacy.  Several  items the designer  must allow for are:

•  lateral loadings
•  wall height
•  deflection limits
•  offset distance (gap) from the panel
•  building movement
•  control joint locations

Wall Height

The overall wall height limit is 12m for both 75mm Hebel Intertenancy 001 and 75mm Hebel Intertenancy 002. The wall shall be constructed of Hebel PowerPanel of 3000mm maximum length. Walls constructed with panel lengths exceeding 3000mm are outside the scope of this guide.

Earthquake Loading

Earthquake loading has not been considered in this design guide. It is the designer’s responsibility to ensure the connection system has adequate capacity to resist any imposed earthquake loading.

Fixings

Fasteners & Fixings
Most screw fixings are timber type, which is sufficient for penetrating the metal thicknesses outlined in this design guide. Connections that have larger metal thicknesses may require a metal type screw and will need to be designed and approved by the project engineer.

Fixings – Deflection head track to substrate
The fixing to secure the angles and tracks to the concrete slab shall be capable of   with  standing  a shear load of 0.75kN. For high wind pressures during construction, the designer shall determine if mechanical fasteners are required:

• Drive pins and concrete nails (check size and suitability for fire rated situations with the manufacturer);
• 8mm diameter mechanical fasteners.

Table 9.1 outlines the connection type and requirements for constructing 75mm Hebel Intertenancy 001 and 75mm Hebel Intertenancy 002 detailed in this design guide.

The core component of Hebel PartyWall systems is the 75mm thick, steel mesh reinforced Hebel PowerPanel. The panel is manufactured in a range of stock sizes with a nil edge profile, as detailed in Table 12.1.

Hebel Mortar

Hebel Mortar is used to provide a level base for panel installation as well as providing acoustic and fire protection at the base of the panels. Used in some 75mm Hebel Intertenancy 001 & 002  wall base arrangements. Supplied in 20kg bags.

Hebel Adhesive

Hebel Adhesive is used for bonding the panels together at vertical joints. Supplied in 20kg bags.

Hebel Patch
Minor chips or damage to panels are to be repaired using Hebel Patch. Supplied
in 10kg bags.

Anti-corrosion Coating Agent
Reinforcement exposed when panels are cut shall be coated with a liberal application of Fentak.

Deflection Head Track
For positioning and restraining the bottom and mid connection of the
panels.  Galvanised deflection head track Rondo Nº498 76 x 50 x 0.75mm BMT or Rondo Nº402 76 x 35 x 0.75mm BMT

Wall Brackets

The brackets are proprietary components which enable the Hebel PowerPanel to be fixed to the wall frame. This provides a cavity space, which can result in increased acoustic insulation  performance. The bracket is nominally 75 x 40 x 1.6mm x 50mm wide aluminium angle. Used in 75mm Hebel Intertenancy 001.

 Top Hat Section

The top hat detailed in this guide is the Lysaght Topspan 22. In 75mm Hebel Intertenancy 002, the top hats are used to fix the Hebel PowerPanel to the structural support framing. For alternative top hat types, the top hat manufacturer or project engineer will be responsible for approving the substitute product as adequate for performance requirements.

In 75mm Hebel Intertenancy 001, the top hats are used to provide easy alignment of the panels during installation. The top hats are installed temporarily between the framing and panels, and MUST BE removed after the aluminium brackets are installed.

CSR Bradford Insulation

75mm Hebel Intertenancy 001 and 002 systems incorporate CSR Bradford Insulation materials. Tables 12.2 and 12.3 present basic information on the glasswool and polyester insulation materials.

Hebel PartyWall systems that use Bradford Glasswool insulation generally have a better acoustic performance than systems using Polyester insulation. Additional information regarding Bradford insulation materials is available from CSR Bradford.

Fasteners & Fixings

Gyprock Plasterboard

75mm Hebel Intertenancy 001 and 002 incorporate Gyprock Plasterboard on both sides. The type, thickness and densities of plasterboard will be as per the specified wall requirements. Additional information is available from CSR Gyprock.

Fire & Acoustic Sealant
To attain the specified FRL and/or Rw requirements, all perimeter gaps and penetrations must be carefully and completely sealed with an appropriate flexible polyurethane (fire and acoustic rated) sealant installed to manufacturer’s specifications.

Backing Rod
Backing rod is used to enable correct filling of joints with sealant. It is recommended that backing rod be of open cell type to enable sealant to cure from behind. The diameter of backing rod must be appropriate for the width of the gap being filled.

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.

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.