1. Design

1.1 Material Properties

• Total Square Metres per Panel = 2.0 m².
• Number of 50mm Panels per Pallet = 23 panels Pallet Weight:- 940kg (approx) (± 20 kg safety factor).
• Pallet Size – 900mm Width x 2250mm Length x Max. 1350mm Height (nom).

1.2 Thermal Performance

The Thermal performance of the QT EcoSeries Wall System is calculated in accordance with AS 2627.1 Thermal Insulation of Dwellings. QT EcoSeries Wall Panel has a k-value of 0.07 w/mk.

1.3 Impact Resistance

QT EcoSeries Wall Panel when coated with a cement base render, can provide resistance for hard body impacts typically found under normal situations.

1.4 Acoustic Performance

The QT EcoSeries Wall System was tested in accordance with AS/NZS 1276.1 for Airborne Sound Transmission and achieved STC41 and R_w41(-3;-8)(Wall Composition: 50mm QT EcoSeries Wall Panel with 30mm (nom) cavity on a 70mm x 35mm stud frame and 10mm plasterboard) CSIRO TL399. Acoustic performance can be significantly increased with the addition of bulk or acoustic insulation batts.

1.5 Fire Performance

QT EcoSeries Wall Panels when tested to AS/NZS 3837 and in accordance with BCA Specification C1.10a Section is classed as a GROUP 1 material.

Early Fire Hazard Indices (Test to AS/NZS 1530 Part 3)

1.6 Durability

In normal conditions and when maintained properly in a weatherproof condition, the cladding systems should exceed 30 years of trouble free serviceable life. When the system is installed in high corrosion zones, such as coastal locations within distances of up to 500m from the sea, particular care must be taken to ensure that openings through the cladding panels are kept to a minimum to prevent corrosive salt aerosols from entering the wall cavity and affecting metal components. (Permitted openings are base weepholes, soffit vents and openings beneath window joinery at sills).

Wildlife Attack

The panels will not support growth of micro-organisms such as fungi or bacteria and do not hold any nutritional value for ants or rodents.

1.7 Cavity

Cavities form an important role in the weathertightness and life cycle of any wall system QT EcoSeries Wall Panels constructed without a cavity will void any warranty. The cavity acts as a secondary barrier against wind driven rain penetration entering the wall framing. The cavity also allows the wall to ventilate and drain which is essential for a healthy wall.

1.8 Vapour Permeable Sarking

Vapour permeable sarking must be installed to the face of the building framing prior to installation of the battens and panels. The vapour permeable sarking has two main functions, weathertightness and thermal resistance. In its weathertightness role it protects the building framing from direct contact with moisture generated by wind driven rain penetration, while allowing the condensation of moisture from interior artificial heating and cooling to escape. Thermally the vapour permeable sarking divides the wall into two separate air spaces, which significantly increases the thermal performance of the wall.

1.9 Weepholes

On the first horizontal course (ground level) weep holes are to be installed at centres not exceeding 1200mm immediately above any damp proof membrane or flashing. Weepholes are also required in areas where there is a possibility of moisture build up. Weepholes must be limited to 8mm in width to reduce the potential for vermin access.

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.