Internal corners can be formed by continuing the QT FullMesh around the corner or by embedding a QT CornerMesh into the base coat render. External corners can be formed by embedding a QT CornerMesh into the base coat render or by fixing a corner bead prior to rendering. In all cases the abutting corner panels must be bonded with polyurethane foam adhesive.

3.2 Relief Joints

Relief joints are required to accommodate any structural movement or panel movement due to temperature or moisture changes. If the panel above or below an opening is less than 300mm in depth or more than 2400mm in length the panel must be articulated by creating a vertical expansion joint to reduce and/or relieve the stress in the panel and coating system. All other corner openings must be reinforced with QT 45˚Mesh. The QT 45˚Mesh helps prevent any 45˚hairline cracks forming from the corner of any opening.

3. 3 Control joints

Control joints are designed to relieve structural movement between the wall cladding and building frame and also relieve any stress that builds up in the applied coating system. Vertical control joints are required at no greater than 5 metre centres (+ or – 500mm) in walls greater than 8 metres in length. Double studs are required at all vertical control joints. Vertical joints are best aligned with windows, doors, openings, or internal corners. Where timber floor joists are used a 15mm (nom), horizontal control joint must be provided at floor levels to allow for shrinkage and movement of the joists. 10mm control joints must also occur where the QT EcoSeries Wall Panels meet alternative wall claddings eg. Weatherboard, brickwork, etc. On gable ends, a horizontal control joint will be required at the top plate of the wall so as to separate the gable wall from the wall below. Control joints can be formed with the use of a backing rod and sealant or by the installation of uPVC expansion bead.

3. 4 Junctions

BGC Compressed Fibre Cement sheeting is immune to permanent damage from water. It is impact resistant, immune to termite attacks, non combustible and easy to work with.

Compressed Fibre Cement:

• high density fibre cement sheeting
• suitable for wet areas
• can be used for cladding external decking
• non combustible
• impact resistant
• easy to work

Unloading Bundles

Panels shall be unloaded and moved with only approved lifting devices. Before use, the lifting device 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 under cover. Care should be taken to avoid sagging or damage to ends, edges and surfaces.

All 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 Hebel PowerFloor panels. Where bundles are stacked two high, the supporting cleats must be vertically aligned, to ensure minimal bending of the lower panels. Refer to Fig 3.

If Hebel PowerFloor panels are stored outside, they 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.

Fig 4.1.1. Stacking Bundles of Hebel PowerFloor

*Unstraping Bundles

Ensure appropriate bracing is installed to bundles prior to removal of strapping to prevent panels from falling. Panels can be held together with sash clamps, ratchet straps or Hebel stabilising bars.

4.2 Panel Handling

Manual Handling

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

• Use mechanical aids, such as trolleys, fork lifts, 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.
• Keep the panels dry.
• Train employees in good lifting techniques to minimise the risk of injury.

Hebel 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 products.

4.3 Tools and Equipment

The basic tools required to assist in the installation of the Hebel PowerFloor are shown in Figure 4.1. These may be purchased through CSR Hebel and include:

1. Mixing bucket
2. Stirrer
3. Trowel
4. Sanding float
5. Panel lifters
6. Levelling plane

Extra equipment will also be required and includes the following:

• Power drill (clutch driven)
• Power saw with metal or diamond tipped cutting blades
• Dust extraction system
• Sockets and bits for screws
• Personal Protective Equipment (PPE) such as goggles, face mask and P1/P2 dust masks, used when site cutting the panels

Fig 4.1.1. The Basic Tools and Equipment Requirements

4.4 Panel Installation

Installation Procedures

CSR Hebel promotes and advocates a safety conscious work place at all times. To assist builders and contractors to maintain their safety standards, CSR Hebel has produced guidelines for the installation and handling of their products. Contact CSR Hebel for additional information.

Mortars & Adhesives

The Hebel bagged mortar and adhesive should be prepared in accordance with instructions on the packaging.

Damaged Panels

Chipped or damaged panels are to be repaired using Hebel Patching Mortar. Your Hebel supplier should be notified immediately of any panel damage or cracking that occurs during the handling of the panels. This damage may result in the panel being structurally inadequate, in which case it must be replaced.

Panel Cutting

Hebel PowerFloor Panels to be cut with a circular saw fitted with a diamond tipped blade. The use of power tools 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 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 hearing protection. Refer to CSR Hebel MSDS sheets.

Reinforcement exposed during cutting is to be coated with a liberal application of Fentak.

4.5 Hebel PowerFloor Installation Sequence

1. Preparation of Framing for Hebel PowerFloor Panel Installation

• Check floor framing is complete and within level tolerances.
• Provide set-out chalk lines, as required.
• Provide temporary installation platform where necessary.
• Ensure floor framing has adequate strength to support Hebel PowerFloor bundles.
• Position Hebel PowerFloor bundles on the floor framing.

2. Hebel PowerFloor Panel Installation

• Panels are to be installed in a stretcher bond pattern, with a minimum overlap of 1 joist space and not less than 450mm.
• Use lifting handles or trolley to move the panels to installation area.
• Apply a 5mm min. bead of Fuller Max Bond construction adhesive (or equivalent) to top of joists in accordance with manufacturer’s instructions, and apply Hebel Adhesive to appropriate panel edges.
• Panels must be installed with minimal horizontal sliding on the joists to ensure a good bond. Force the tongue and groove joint closed as the panel is rolled and lowered onto the joists. Ensure all joints are tight and that adhesive makes full contact along all joints.
• Screw fix panel to the joists as required.
• Repeat process, removing excess Hebel Adhesive.

3. Penetration Detailing

• Install blocking to support Hebel PowerFloor panel at major openings.

4. Floor Finishes

• Sweep the floor surface to remove debris and loose particles.
• Fill joints and screw holes with Hebel Adhesive, as required.
• Ensure perimeter is not chipped.
• Install floor covering for Hebel PowerFloor system in accordance with manufacturer’s specifications.

Note: Ensure panel moisture content is within limits outlined by the floor covering manufacturer.

Where it is proposed to construct single dwellings side-by-side on a single allotment the internal wall between dwellings is a fire separating wall as defined in the BCA. The fire separating wall must start from the ground level (top of concrete footings or top of floor slab) and achieve a 60/60/60 FRL if load bearing, or –/60/60 FRL if nonload bearing. The wall must go to the underside of a non-combustible roof covering and any gaps be filled with fire resisting material as described in Detail 3.7.1.11 of Volume Two of the BCA.

Dwellings Constructed Side-By-Side on Separate Allotments

Where it is proposed to construct single dwellings side-by-side on separate allotments, or if subsequent subdivision is proposed, the wall might also be considered an external wall and each dwelling may be required to have its own wall starting from the ground level (top of concrete footings or top of floor slab) and each achieving a 60/60/60 FRL if load bearing, or –/60/60 FRL if non-load bearing. Contact your local authorities, as there may also be applicable legislation or discretionary powers available to vary these provisions.

Dwellings Constructed Side-By-Side on a Single Allotment Where Subdivision May Subsequently Occur.

Where it is proposed to construct single dwellings side by side on a single allotment and it is known that subsequent subdivision will occur, or that subdivision might occur (and this will probably apply to most multi-dwelling developments) then, after subdivision, the internal fire separation wall might also be considered an external wall and each dwelling may be required to have its own wall starting from the ground level (top of concrete footings or top of floor slab) and achieving a 60/60/60 FRL if load bearing, or –/60/60 FRL if non-load bearing. Contact your local authorities, as there may also be applicable legislation or discretionary powers available to vary these provisions.

Hebel PartyWall Solutions in tiered applications

Where the internal fire separation wall extends beyond the roof line on one side only and becomes an external wall, contact CSR Hebel Engineering Services for advice on PowerWall external wall solutions.

Compliance with the Building Code of Australia (BCA)

All building solutions, such as walls, floors, ceilings, etc. must comply with the regulations outlined in the Building Code of Australia (BCA) or other authority.

The BCA is a performance based document, and is available in two volumes which align with two groups of ’Class of Building’: Volume 1 – Class 2 to Class 9 Buildings; and Volume 2 – Class 1 & Class 10 Buildings – Housing Provisions. Each volume presents regulatory Performance Requirements for different Building Solutions for various classes of buildings and performance provisions.

These Performance Provisions include:

• Structure
• Fire Resistance
• Damp & Weatherproofing
• Sound Transmission & Insulation
• Energy Efficiency

This design guide presents tables and information necessary to design a Hebel PartyWall installation that complies with the Performance Requirements of the BCA. The designer must check the adequacy of the building solution for Performance Requirements outlined by the appropriate authority.

Detail 4.1: Typical Applications.