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AUGUST 2012EXTERNAL FACADE SYSTEM (INCLUDING CEMINSEAL BARESTONE™)

CSR CEMINTEL™

EXPRESSWALL FC:126

Cemintel ExpressWall™ offers an expressed joint facade system for an extensive range of commercial and industrial applications. Panels available are ExpressPanel™, which can be painted on-site, and BareStone™, a pre-finished panel with a raw concrete appearance.

2 CEMINTEL EXPRESSWALL™

CoNTENTSDescription 2

ApplicAtions 2

expressWAll™ ADvAntAges 3

components 4–6

Design consiDerAtions 7–14

top HAt FrAming 15–16

pAnel prepArAtion 17–19

pAnel instAllAtion 20–23

curveD FAcADes 24

construction DetAils 25–32

Fire rAteD WAll systems 33–36

ArcHitecturAl speciFicAtion 37

mAteriAl properties 38

HAnDling & storAge 39

sAFety 39

pAnel cutting 39

HeAltH & sAFety 40

guArAntee 40

DESCRIPTIoNFocused on taking a fresh look at the building market, CSR Cemintel™ has a range of products that make buildings look great and work better.

Cemintel’s range of creative products have ‘a look’, finishes that inspire people, which they aspire to have on and in their buildings. Whether it be the unique colours and textures provided by the Designer Series or the traditional weatherboard look of Scarborough, CSR Cemintel has the products to help you create a stunning facade.

Drawing upon the best knowledge in the industry, CSR Cemintel constructive solutions improve the speed in which buildings are built and the way they work. Ranging from the industry first CeminSeal, which provides 95% stronger joint and compound adhesion to Permafloor, a new lightweight structural flooring product that can be gun nailed for ease of installation, Cemintel people consistently challenge themselves to take a fresh look at solving key industry issues.

APPLICATIoNSThe Cemintel ExpressWall™ system has been designed to be used for external cladding buildings such as:

• SupermarketsandShoppingcentres.• OfficeBuildings.• MostCommercialBuildings.• ResidentialHomesandApartmentBuildings.• OranyotherapplicationnotexcludedbytheDesign

Considerations section of this brochure.

It however remains the responsibility of the building designer to verify the Cemintel ExpressWall™ system is suitable for the particular requirements of any given project.

The Cemintel ExpressWall™ System has excellent resistance to water penetration and high wind loads, and is suitable for exposed applications.

The ExpressWall™ System can also be used as an exterior ceiling. Contact CSR Gyprock & Fibre Cement for details.

CEMINTEL EXPRESSWALL™ 3

DESIGN FEATURES• Expressedjointappearance.

• Flat,smoothfinishwithcountersunkscrews.

• Readilyacceptsmanyformsofdecorativefinish.

• ExposedheadfastenersforBareStone™ and pre‑painted panels.

• Pre-finishedBareStone™ with natural cementitious appearance.

• Testedweatherresistance.

• Designedforextremewindpressures.

• Lightweight,lowmaintenancefacadesystem.

• Suitableforcurvedapplications.

CONSTRUCTION FEATURES• Highlydurablegaskets.

• Dimensionallyaccuratepanels.

• Highprefabricationopportunity.

• Panelseasilyreplaced.

• HighperformanceExpressWall™TopHat1.15:

–SuitableforCyclonicAreas.

– Wide fixing surface for increased installation tolerance.

EXPRESSWALL™ ADvANTAgES

ExpressWall Backing Strip

Structural support

ExpressWall Horizontal Gasket

ExpressWall Vertical Gasket

Adhesive

ExpressWall Top Hat

Intermediate Top Hat

Sarking

ExpressPanel™ or BareStone™ Panel

Countersunk HeadFastener

Exposed HeadFastener


EXPRESSPANEL™

ExpressPanel™ is a compressed fibre cement sheet which is purpose manufactured for use in building facades. ExpressPanel™ is factory sealed on both faces and all edges. The white face is ready to accept a wide range of finishes. ExpressPanel™ is 9mm thick, has a mass of 17kg/m2, and is available in the following panel sizes;

CeminSeal BareStone™ Sizes. (All panels 9mm thickness)

Width (mm)

Length(mm)

1800 2100 2400 2700 3000

900 3 3 3

1200 3 3 3 3 3

note: please contact csr gyprock & Fibre cement for nonstandard expresspanel™ sizes.

ExpressPanel™ Face Identification

CEMINSEAL BARESTONE™ PANELCeminSealBareStone™ Panel is a compressed fibre cement sheet which is purpose manufactured for use in building facades.CeminSealBareStone™ Panel has water blocking agents embedded in the sheet and does not require a finish tobeapplied.CeminSealBareStone™ Panel is 9mm thick, hasanaturalfibrecementcolour(grey),amassof17kg/m2, and is available in the following panel sizes.

CeminSeal BareStone™ Sizes. (All panels 9mm thickness)

Width (mm)

Length(mm)

2400 3000

1200 3 3

note: please contact csr cemintel for non-standard ceminseal Barestone™ panel sizes.

CeminSeal BareStone™ Back Face Identification

The back face of the panel is clearly marked

BARESTONE™ TOUCH-UP KITForcoatingtheedgesofBareStone™ panels that have been cut on‑site.

OrderN° Quantity

100166 200ml

CoMPoNENTS

White outside face suitable for coating

Outside face

Clear finish to inside face – Not suitable for coating


20 2050

15

EXPRESSWALL™ TOP HATExpressWall™TopHatisapurposedesignedrolledsteelsection for supporting the vertical edges of the panels. The unique profile also acts to accommodate movement of the sheets at the vertical joints. It is designed to be used in conjunction with the ExpressWall™ Vertical Gasket.

ExpressWall™TopHatismanufacturedfromgalvanised(Z275)steel,andisthesubjectofpatentapplicationNº2003900205.

ExpressWall™TopHat1.15BMTisrequiredforcyclonicareasand when exposed head screws are to be used, including all BareStone™ installations.

BMT OrderNº Length(m) Masskg/m

1.15 39124 6.0 3.25

0.75 84746 6.0 1.97

INTERMEDIATE TOP HATIntermediateTopHat isusedtosupportthepanelsatlocationsotherthanverticaljoints.IntermediateTopHatisa Rondo rolled steel section which is manufactured from galvanised(Z275)steelof1.15mmBMT.


1.15 21086 3.6 1.38

1.15 21083 72 1.38

TOP HAT H515TopHatH515isfixedtostructuralsteelframingtosupportthe ExpressWall™andIntermediateTopHats.TopHatH515is a Rondo rolled steel section which is manufactured from galvanised(Z275)steelof1.15mmBMT.


1.15 12884 3.6 0.91

1.15 100896 7.2 0.91

EXPRESSWALL™ VERTICAL GASKETExpressWall™ vertical gasket is made fromEPDMclosedcellfoam which has high UV resist ance. The gasket has adhesive on one side (with a release paper), and is adhered to the ExpressWall™TopHattopreventmoisture entry at vertical joints.

OrderNº Description

221063.2mmx48mmx25mroll

(Tesa61102)

EXPRESSWALL™ HORIZONTAL GASKETExpressWall™ horizontal gasket is madefromclosedcellPVCNitrilefoam which has a high resist ance to abrasion and maintains i ts properties at high temperatures. The gasket has adhesive on one side (with a release paper), and is adhered to the ExpressWall™BackingStriptopreventmoistureentryathorizontal joints.

OrderNº Description

221053.0mmx18mmx9mroll

(Tesa50601)

EXPRESSWALL™ BACKING STRIPExpressWall™BackingStripisarolledsteelsection designed to support the gasket and/or sealantbehind thehorizontalexpressed joints. ExpressWall™BackingStrip is manufactured from high tensile Colorbond steel, and is black in colour.

OrderNº Length

21089 1194mm

21088 2394mm

21087 2994mm

20 2050

35

2222 295529

35

59

1711.15 BMT

5252 246 6 24

35

53

163

0.75 BMT

60mm


EXPRESSWALL™ SCREWSExpressWall™ Screws are specially designed for the ExpressWal l™ System. They a re the on ly screws recommended by CSR for f ixing ExpressPanel™ and BareStone™ panels to the steel top hats.

Countersunk Head Screw:

TheCountersunkHeadallowsconcealedfixing,andthebuttress thread is designed to provide maximum holding power in light gauge steel. It has a Class 3 finish and is gray in colour. For ExpressPanel™ only.

OrderN° Description

114070CountersunkHeadClass3

Finish1000/pack

Exposed Head Screw: (Suitable for ExpressWall™TopHat1.15.ONLY).

TheExposedHeadScrewhasabuttressthreadwhichisdesigned to provide maximum holding power in light gauge steel. It is available in Class 3 finish and Stainless Steel (grade410).ForExpressPanel™andBareStone™ panels


114081WaferHeadClass3Finish

1000/pack

28626WaferHeadStainlessSteel

1000/pack

EXPRESSWALL WEATHER SEALThe ExpressWall™ Weather Seal is a grey, UV stabilised nylon washer. I t is used wi th ExpressWal l™ ExposedHeadScrewstoprovidean interference fit, delivering high weather resistance and acting to lock the screw into position.


36484 Weather Seal

HEX HEAD SCREWFor f ixing top hats to steel framing in non‑cyclonic areas. Hexheadselfdrillingscrew12-14x20.(Suitabilitytobeconfirmed by project engineer).

OrderN° Qty

84882 1000

COUNTERSINKING TOOLThis is a tungsten carbide tipped tool specifically designed for drilling and countersinking the required 6mm diameter screw ho les inExpressPanel™. It is suit able for use with screw guns and drills, and has an adjustable depth setting. This is the only tool recommended by CSR for this purpose. Use only for countersunk head screws


22116 Countersinking Tool

BACKING STRIP ADHESIVEAnadhesiveisusedforfixingExpressWall™BackingStriptopanels.TherecommendedproductisSikaflex®-11FC.Thisproduct is not recommended for filling expressed joints.


39378 Sikaflex®11FC,310mltube

SARKINGBradfordfoilproductsareusedtoprovidethermalinsulationandmoistureprotection.Thermofoil733isadoublereflectivefoil for high thermal rating.

Product OrderN° Qty

EnviroSeal™ Wall Wrap

13462 1350mmx20mroll

Thermofoil733 81333 1350mmx60mroll

30mm

Class 3 finish

30mm

Stainless Steel

30mm

Class 3 finish

To Suit Hole


40mm

20°

20mm

40mm

CAVITY BAFFLEPVC prof i le used at base of wall to exclude vermin and moisture.

OrderN° Length

38651 3.0m

SEALANTSealant is used to seal ExpressWall™ joints for high wind loads, control joints, junctions, etc. Can be painted over with most paints. It is also required at expressed joints where prepainted ExpressPanel™ has been used.


11378 Sikaflex®PRO,310mltube(colourGrey)

39488 Sikaflex®PRO,310mltube(colourBlack)

Othersealantsmaybeusedfordecorativepurposes,whenapproved by the manufacturer.

EPOXYEpoxy is used to conceal the countersunk fastener heads, to prevent moisture penetration, and to provide a flat surface for decorative coating. Epoxy products must be installed to the manufacturer’s recommendations.

Recommended products are:• MegapoxyP1.• HiltiCA125*.• HiltiCA273*(shouldbeusedwhenambient

temperatureislessthan15°Cattimeofinstallation)


25464 MegapoxyP1,1litrekit

BOND-BREAKER TAPEBond-breakertapeisusedbehindsealantathorizontaljoints,forexamplewhenthedesignwindpressureexceeds4.0kPa.


13172Tesa7492

(3.2mmx48mmx25m).

BACKING ROD*

Backingrodisusedtoenablecorrectfillingofjointswithsealant. 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.

FLASHINGS & CAPPINGS*Flashings are to be designed and installed in accordance with SAA-HB391997andgoodbuildingpractice.

*NotsuppliedbyCSR.

DESIgN CoNSIDERATIoNSThis guide represents good practice, though it is not intended as an exhaustive statement of all relevant information. It remains the responsibility of the building designer to verify that the Cemintel ExpressWall™ system is suitable for the particular requirements of any given project.

DESIGN RESPONSIBILITYPanels, top hats and structural framing are required to resist windloadsthatarespecifictothebuildingsite.Additional‘local pressure factors’ apply to the panels and top hats in accordancewiththewindcode,AS1170.2.Itisrecommendedthat the building designer assigns responsibility for the facade design to the project engineer. This is to ensure consistency of wind load determination and proper integration of the facade with the structure.

Oncewindloadshavebeendetermined,tophatspansandspacings, and sheet fixing details, may be selected from the appropriate tables in this manual.

It is also the responsibility of the building designer to select theappropriatecorrosivitycategory.RefertoTable1, onpage10.


HIGH WIND LOADSInareaswherethedesignwindpressuresexceed4.0kPa,additional sealing is required to minimise water ingress. Refer toFIG31and32foradditionaldetails.

In cyclonic areas ExpressWall™TopHat1.15mmmustbe used.

Windloadsinthisguidereferto‘UltimateLimitStateDesignWind Pressures’.

SARKINGThe ExpressWall™ facade is designed as a rain screen, and if exposed to weather, appropriately designed sarking must be used between the top hats and the framing. If the wall is not exposed directly to the weather and will not get wet during storms, sarking is only required for insulation and condensation control. Sarking must be designed and installedinaccordancewithAS/NZS4200Part1:Materials,and Part 2 : Installation.

Condensation is a complex problem, and can occur under avarietyofconditions,notjustcoldconditions.LiteratureonthissubjectisavailablefromCSIRO/BRANZ/ASHRAEand must be consulted when building in areas where condensation is likely to occur.

In these cases, the appropriate use of a sarking as a vapour barrier or as thermal insulation, or both, can be effective in controlling condensation.

THERMAL PERFORMANCE

expressWAll™

•1layerorBareStone™ or ExpressPanel™ fixed to Cemintel ExpressWall™ top hat framing system.

•InsulationandSarkingaspersystemtable.

•TimberorSteelStuds(90mmmin.)at600mmmaximumcentres.

•1layerx10mmGYPROCKplasterboardCDfixedtotheinsideofframing.

Insulation in Cavity Sarking Winter

Total Wall R-Value

Summer Total Wall R-Value

(a)NilBRADFORDENVIROSEALWallWrapunder top hats

1.2 1.0

(b)NilBRADFORDTHERMOFOIL733undertop hats

1.7 1.4

(c)BRADFORDGold battsR1.5

BRADFORDENVIROSEALWallWrapunder top hats

2.1 1.9

note: *Bradford thermofoil 733 is sarking with reflective finish both sides. using an alternative product with anti-glare finish will reDuce the stated r-value performance.

INSULATIONIt is recommended that insulation materials be installed to enhance thermal insulation properties and occupant comfort. Insulation also improves the acoustic performance of the wall against outside noise.

The level of insulation provided in a wall is determined by its R‑value. The higher the R‑value the greater the insulation provided. Cemintel ExpressWall™ Systems incorporating BradfordR1.5GoldInsulationcanprovideathermalratingofR2.1,whichisgreaterthanmanymasonrysystems.

PANEL FINISHES

• ExpressPanel™

ExpressPanel™ is factory sealed on both faces and all edges. Sealing in this manner increases the durability and stability of the panels. The exterior surface of the ExpressPanel™ must becoatedwithanappropriatefinish.Notethatthebackface of panels cannot be painted, and is not suitable as an exterior finish.

Where panels are cut on‑site, sealing of the cut edges shall bewithDuluxAcra-Prime501/1.Theminimumapplicationrateshallbe1litreper10m2(140grams/m2)whichresultsinadryfilmthicknessof70microns.Alternatively,coatwithundilutedBondcretebeforeapplyingthefinishcoating.


The exterior face of ExpressPanel™ can be finished with any of a wide variety of coatings, provided they are compatible with the ExpressPanel™ seal coat, ExpressWall™ screws and with the epoxy used to cover the countersunk heads. Highbuild,exteriorgradeacrylicpaintoraggregatefinishesprovide the best results. Exposed vertical gaskets should not be painted and Sikaflex Pro sealant may be painted if required

ExpressPanel™ may be painted off‑site when exposed head screws are to be used. Refer to appropriate painting contractors for details and colours. For pre‑painted panels, it is a requirement that all expressed joints are filled with sealant. Refer to Panel Installation.

Aminimumdryfilmthicknessof250micronsisrecommendedtoensureadequatecoverfortheconcealedfasteners.Highgloss and low build finishes will require additional surface preparation to minimise fastener show‑through. In all cases the coating manufacturer’s application instructions must be followed. The inside face of the ExpressPanel™ is finished clear and is not suitable for painting.

Beforeapplyingfinishesincoastalareas(refertodefinition),all panels must be thoroughly washed with fresh water to remove any salt residue. Refer to coating manufacturer for additional requirements.

• BareStone™

TheproductionofCeminSealBareStone™ panels incorporates waterblocking agents that are embedded in the sheets. That is, the panels are delivered ready to install and do not require afinishapplied.Notethatthebackfaceofthepanelisclearlymarked. It may exhibit production marks and should not be confused with the front.

Where panels are cut on‑site, treatment of the cut edges is required.ApplyBareStone™Touch-upKitliberallybybrush.

CONTROL JOINTSControl joints in the ExpressWall™ system are required to correspond to control joints in the supporting structure and anywhere that significant structural movement is expected.

Ahorizontalcontrol joint is requiredbeneathslabstoaccommodate any expected deflection. The magnitude of the deflection must be verified by the building designer. RefertoFIG35and36.

Vertical control joints to allow for differential movement are required at the supports of fascia trusses and at the junction of structural elements of different stiffness, such as between concrete columns and stud frames.

RefertoFIG40,4142and50.

DURABILITYCemintel ExpressPanel™&CeminSealBareStone™ panels have many properties which make them very durable products, including:

•Immunetopermanentwaterdamageinbothshortandlong‑term exposure.

•Willnotrot,burnorcorrode,andisunaffectedbytermites, air, steam, salt and sunlight.

•Notadverselyaffectedoveratemperaturerangeof0ºCto95ºC.

MAINTENANCEThe durability of the ExpressWall™ system can be enhanced by periodic inspection and maintenance. Inspections should include examination of the coatings, flashings and seals. Paint finishes must be maintained in accordance with the manufacturer’s recommendations.

ThenaturallookofBareStone™ panels is expected to change little over time, and the original appearance can generally be maintainedbywashingwithwater.Notethatifdetergentsareused they should be removed with clean water.

BareStone™ panels may also be coated with a water based exterior‑grade acrylic paint or a clear sealer, and then maintained in accordance with the manufacturer’s specifications. The coating product must have suitable durability and be recommended by the manufacturer for use with masonry substrates.

Anycrackedordamagedfinishorsealswhichwouldallowwater ingress, must be repaired immediately by recoating or resealing the effected area, or by removing the panel and replacinggaskets.Anydamagedflashings,sheetsorgasketsmust be replaced as for new work.

For details on system requirements in different environments refertoTable1.Itisthedesigner’sresponsibilitytodeterminethe Corrosivity Category, based on site conditions.

The durability of the system can be increased by the additional treatment of steelwork, and by painting all exposed sealants to the sealant manufacturer’s recommendations. In corrosivity category C4, barriers to reduce the ingress of salt laden air are required.


Table 1: Requirements for Corrosive Environments

Corrosivity Category(AS4312)

ExposedHeadScrews

CountersunkScrews Joints Additional

Maintenance

C1:VeryLowC2:Low

Class 3 or Stainless Steel Class 3 Sealed or Expressed –

C3:Medium Class 3 or Stainless Steel Class 3 Sealed or Expressed Wash‑down

C4:High Stainless Steel Class 3 Sealed Wash‑down

C5:VeryHigh NotSuitable NotSuitable – –

TableNotes:•SealedJoints:Allhorizontalandverticaljointsmustbecompletelyfilledwithsealant.RefertoFIG31and32.•Wash-down:•Allwallsmustbesufficientlyexposedfromabovesothatraincanperformnaturalwash-downofthewall. OR•Wallswhichareprotectedbysoffitsabovemustbewasheddowntwiceperyear,toremovesaltanddebrisbuild-up,particularlyatjoints.

CORROSIVITY CATEGORIESCorrosivitycategoriesareasdescribed inAS4312 -AtmosphericcorrosivityzonesinAustralia.Thecodehasmethods for determining categories as well as maps and tables of major population centres.

C1: Very Low

Generally inside buildings, semi‑sheltered locations away from marine or industrial influence, and some alpine regions.

C2: Low

Dry, rural areas, away from the coast or sources of pollution. MostareasofAustraliaatleast50kilometresfromthecoast,which can extend to within one kilometre from quiet, sheltered seas.Most inlandtowns,suchasCanberra,Ballarat,ToowoombaandAliceSprings,andsuburbsofcitiesonshelteredbays(Brisbane,Melbourne,Hobart)thataremorethanonekilometrefromthesea.Adelaidesuburbsmorethan6kilometresfromthecoastinthesouthernsuburbs,throughto 3 kilometres from the coast in the northern suburbs.

C3: Medium

Coastal areas with low salinity, extended by factors such as wind, topography and vegetation. Sheltered areas such asPortPhilipBay50metresfromtheshorelinetoaboutonekilometreinland.Aroundlessshelteredbayssuchas

Adelaidetoabout3to6kilometresinland.Alongoceanfrontareas with breaking surf and significant salt spray extending fromaboutonekilometreinlandtobetween10and50kilometres inland, depending on the strength of prevailing winds and topography. Includes much of the metropolitan areasofWollongong,Sydney,NewcastleandtheGoldCoast,mostoftheYorkePeninsulaSouthAustralia,andfromVictorHarbourtotheVictorianborder,extendingbetween30and70kilometresinland.Urbanandindustrialareaswithlow pollution levels, and for several kilometres around large industries such as steelworks and smelters.

C4: High

Aroundshelteredbaysupto50metresinlandfromtheshoreline.Areaswithroughseasandsurf,extendingfromseveral hundred metres inland to about one kilometre inland and depends on winds, wave action and topography. Up to 1.5kilometresdownwindoflargeindustrialplants.

C5: Very High

Offshoreandonthebeachfrontinregionsofroughseasandsurf beaches, and inland for several hundred metres, e.g. aroundNewcastleextendingoverhalfakilometrefromthecoast.AggressiveindustrialareaswheretheenvironmentmaybeacidicwithapHoflessthan5.


STRUCTURAL SUPPORTExpressWall™TopHatsandIntermediateTopHatsmustbeinstalled vertically, and supported by a primary structural system.

ExpressWall™ top hats can be fixed to horizontal structural steel framing which is commonly used for large walls and buildings.

FIG 1: Fixing to Structural Steel Framing

ExpressWall™ framing can also be fixed over masonry or concretewalls.Alltophatconnectionsmustbedesignedbythe project engineer.

FIG 2: Fixing to Existing Masonry Wall

Concrete footing

ExpressWall Top Hat


Structural steel frame

ExpressWall Top Hat


Masonry wall


Alternatively, ExpressWall™ framing can be f ixed to appropriately designed steel or timber framing. This is commonly used for small walls and buildings. The frame must be designed to support the top hats at the top and bottom of the wall, and at cross members within the span of the wall. The connection of the cross member to the frame requires engineering design.

AS/NZS1170.0TableC1suggeststhatsupportframingbedesignedforamaximumdeflectionofspan/250.

Table 2: Vertical Spacing of H515 Top Hats – Horizontal Top Hats Fixed to Three or More Studs

WindLoadkPa

VerticalSpacingofH515TopHats(mm)

StudSpacing(mm)–Studs0.75BMT StudSpacing(mm)–Studs1.15BMT

300 450 600 300 450 600

1.0 3040 2020 1520 4640 3090 2320

1.5 2020 1350 1010 3090 2060 1540

2.0 1520 1010 760 2320 1545 1160

2.5 1210 810 600 1850 1230 920

3.0 1010 670 500 1540 1030 770

3.5 860 570 430 1320 880 660

4.0 760 500 380 1160 770 580

4.5 670 450 330 1030 680 510

5.0 600 400 300 920 610 460

5.5 550 360 270 840 560 420

notes: top Hat to stud connection is 2 x nº12g screws through top hat legs. Wind loads are ultimate limit state. top Hat serviceability deflection < span / 240. stud frame design by others.

FIG 3: Fixing to Steel or Timber Framing

Concrete footing

Structural steel frame

Top track


ExpressWall Top Hat

Bottom track

Top Hat (H515)

Top Hat (H515)

Top Hat (H515)

Top Hat (H515)


PANEL LAYOUTPanel layout for the ExpressWall™ system involves the coordination of the following:

•Aestheticdesign.•Tophatspacingtoallowforexpressedjointwidths.

Refer to FIG: 4.•BareStone™ and ExpressPanel™ size and joint width.

(Horizontaljointsare10to20mmwideandverticaljointsare6to20mmwide).

•Typeofstructuralsupport.•Openings–sizeandlocation.•Buildingsize.•Buildingcontroljointlocation.

FIG 4: Typical Top Hat Set-out – 1200mm Width Vertical Panels with 10mm Joints shown

605mm 605mm

1200mm Sheet

Furring Channel Spacing

Furring Channel Spacing

FIG 5: Horizontal Sheeting Aligned Grid Pattern

FIG 6: Horizontal Sheeting Half-bond Pattern

Panel layout can be in a grid pattern where vertical and horizontal joints are continuous. Panels may be positioned vertically,horizontallyorrotatedupto45ºintheplaneof the wall.

In these layouts, construction joints may be positioned behind any vertical or horizontal sheet joint. For details on control joints, refer to page 29.

Panel layout can also be in a vertical or horizontal half‑ bond pattern where some joints are discontinuous.

FIG 7: Vertical Sheeting Aligned Grid Pattern

FIG 8: Vertical Sheeting Half-bond Pattern


GASKETSGaskets are used at horizontal and vertical joints to maintain weather resistance.

Theverticalgasket ismadefromEPDMrubberwhichhas good weathering and UV resistance. It has very low compression set and water permeability.

ExpressWall™TopHat1.15hasbeendesignedtoelasticallydeform when pressure is applied during panel f ixing. ExpressWall™TopHat0.75hasarecessedareatoacceptthe gasket. These designs ensure that only the required pressure is applied to the vertical gasket.

FIG 9: Vertical Gasket Compression

FIG 11: Joint Detail

Thehorizontalgasket isaclosedcellPVCNitrilefoamwhich has a high resistance to abrasion and maintains its properties at high temperatures. It is highly conformable and has excellent resistance to water penetration.

FIG 10: Horizontal Gasket Compression

ExpressWall Top Hat 1.15

Vertical Gasket

ExpressWall Countersunk Screw

Panel

Horizontal Gasket

Backing Strip

Panel

Panel

Backing Strip and Gasket deform to create effective seal




Sikaflex-11FC

ExpressWall Top Hat

ExpressWall Fastener

ExpressPanel or Barestone panel


ToP HAT FRAMINgThe design capacities of the ExpressWall™ system are in limit stateformatandintendedforusewithAS/NZS1170.2.Thesystem is suitable for cyclonic wind zones, Region C and D, andhasbeentestedinaccordancewithAS4040.31992.

To obtain equivalent permissible load capacity divide the ‘UltimateWindCapacities’inTable3orTable4by1.5.

The top hat capacities in Table 3 and Table 4 have been calculated inaccordancewithAS4600:ColdFormedSteelStructuresandareapplicablefor0.75and1.15BMTExpressWall™TopHatsandfor1.15BMTIntermediateTopHats.ThedeflectionofthetophatsasdetailedinTable3andTable4isnomorethanspan/250whensubjectedtoserviceabilitywindloadsof68%ofultimatewindloads.

TABLE 3: Ultimate Wind Capacity (Refer to FIG 12)

Single Span Installation

TopHatSpan(mm)

NominalTopHatSpacing*

450mm 600mm

Ultimate WindCapacity

(kPa)


(kPa

9009501000

6.006.005.41

3.503.503.50

110012001300

4.143.182.42

3.142.411.83

140015001600

1.871.481.19

1.421.120.91

170018001900

0.980.810.69

0.740.620.52

200021002200

0.580.500.44

0.440.380.33

*Nominaltophatspacingsof450mmand600mmaresuitableforactualspacingsofupto460mmand610mmrespectively.Forpanelsfixedtoaminimumofthreetophats,withtophatspacingof400mmnominal(410mmmax.),andwithsingleordoubletophatspanofupto900mm,theultimatewindcapacityis7.0kPa.

FIG 12: Single Span Installation

Top Hat Spacing

Top Hat Span (Table 3)

Cantilever

Cantilever

Maximum Cantilever = 0.2 x Adjacent Top Hat Span


TABLE 4: Ultimate Wind Capacity (Refer to FIG 13)

Double Span Installation

TopHatSpan(mm)

NominalTopHatSpacing*

450mm 600mm


(kPa)


(kPa

9009501000

6.006.006.00

3.503.503.50

110012001300

5.844.914.18

3.503.503.17

140015001600

3.603.142.76

2.732.382.09

170018001900

2.442.131.77

1.851.621.34

200021002200

1.491.261.08

1.130.960.82

*Nominaltophatspacingsof450mmand600mmaresuitableforactualspacingsofupto460mmand610mmrespectively.Forpanelsfixedtoaminimumofthreetophats,withtophatspacingof400mmnominal(410mmmax.),andwithsingleordoubletophatspanofupto900mm,theultimatewindcapacityis7.0kPa.

TOP HAT FIXING (Refer to FIG 14)

note: it is the responsibility of the project engineer to specify the connection of the top hats to the support structure.

Eachfastenerisrequiredtohaveaminimum14mmdiameterhead,suchasa12ghexheadscrew,forsatisfactorytophatperformance.Incyclonicareas,minimum14ghexheadscrewsand1.15BMTtophatsarerequired.

FIG 14: Top Hat Fixing

FIG 13: Double Span Installation

If adjacent spans differ by more than 25% then single span values must be adopted.

MaximumCantilever=0.2xAdjacentTopHatSpan

Cantilever

Cantilever

Top Hat Spacing



Fixing

ExpressWallIntermediate Top HatFixing

ExpressWall Top Hat


PANEL PREPARATIoNExpressPanel™andBareStonepanelpreparationmaybeperformedoff-sitepriortoinstallation.Allcutpanelsmusthave edges painted as noted in Panel Finishes.

Prior to lifting into place:1.Drillholesthroughthepanelsforscrews,and

countersink if required.2.Affixhorizontalgaskettobackingstrips.3.Affixbackingstripsbehindthetopedgeofpanelsand

allow adhesive to set.

PANEL FIXING SET-OUTPanelsmustbefixedinaccordancewithTable5.Appropriatepanel fixing layout should be selected for the project Design WindPressure,TopHatSpacingandPanelFixingType.(RefertoFIG16and17).

For curved facades, please refer to page 24.

Table 5: Panel Fixing Requirements

Design Wind Pressure (Ultimate)

(kPa)

Max.TopHatSpacing(mm) Max.FixingSpacing(mm)

Panel Fixed to TwoTopHats SeeFIG16.

Panel Fixed to ThreeormoreTopHats

SeeFIG17.

at Panel Edge ‘X’ (mm)

atIntermediateTopHat ‘Y’

(mm)

1.0

1.5

600

450

600

600

600

600

600

600

2.0

2.5

450

450

600

600

400

400

400

350

3.0

3.0

450

450

600

450

400

400

300

400

3.5

3.5

400

400

600

450

300

350

250

350

4.0

4.5

400

400

450

450

300

300

300

250

5.0

5.5

300

300

450

450

300

250

200

200

6.0

6.5

7.0

300

300

300

450

400

400

250

250

250

200

200

200

FIG 16: Panel Fixed to Two Top Hats Only

FIG 15: Panel Fixing Set-out

*Minimumdistanceoffastenertoedgeof35mm.

FIG 17: Panel Fixed to Three or More Top Hats

45mm*

45mm*

45mm*

Fixing Spacing at Panel Edge (refer to Table 5)

Fixing Spacing at Intermediate Top Hat(refer to Table 5)

‘X’

‘Y’

* Minimum distance of fastener to edge of 35mm.

Top Hat spacing Top Hat spacingTop Hat spacing


PRE-DRILLING HOLESHolesforscrewsmustbepre-drilled.Usetherecommendedcounter sinking tool for countersunk head screws, and a 6mmmasonrybitforexposedheadscrews.Holesmustbe6.2mmto6.3mmindiameter.Donotusehammeractionwhen drilling. Clean dust out of holes.

FIG 18: Fastener Pre-drilling for Countersunk Head Screws

note: use only the recommended tool as supplied by csr. the use of other tools for this purpose may reduce fixing capacity or reduce the weather resistance of the system.

HINT:Onewayofdrillingholesistodrillthetopsheetofapackwiththecountersinkingdrillsettoapproximately12mmdepth. This will give a starter hole on the sheet below, saving on set out time.

FIG 19: 6mm Masonry Drill for Exposed Head Screws

BACKING STRIP FIXINGBackingstripisinstalledbehindallhorizontalpaneljoints.Backingstripistobe6mmshorteroverallthanthewidthofthe panel (cut to length if necessary) and adhered to the back ofthepanel(alongthetopedge)withSikaflex-11FC.

FIG 20: Backing Strip Positioning

Backingstrip isadheredtothebackofpanelswithacontinuousbeadofSikaflex-11FC.Thebeadmustbeasuitable size so that when pressed flat, adhesive fully covers the interface between the backing strip and the panel. The adhesive must be allowed to cure before the panel is installed.

Note: Use only the recommended tool as supplied by CSR. The use of other tools for this purpose may reduce fixing capacity or reduce the weather resistance of the system.



mm3mm3

Panel

5mm

Panel

Backing Strip

For 10mm Horizontal Joint

For 20mm Horizontal Joint

Note: Use only the recommended tool as supplied by CSR. The use of other tools for this purpose may reduce fixing capacity or reduce the weather resistance of the system.

6mm


AfilletofSikaflex-11FCisthenplacedalongthetopedgeofthe panel. This ensures that the joint drains and that salt and dirt will not build up at the joint.

FIG 21: Horizontal joint

HORIZONTAL GASKET FIXINGApplytheExpressWall™HorizontalGaskettotheuppersection of the backing strip, keeping the gasket in line with thetopofthebackingstrip.(Alternatively,thiscanbedoneprior to fixing the backing strip to the panel).

FIG 22: Horizontal Gasket Installation

SEALING ENDS OF BACKING STRIPTo seal the groove in the backing strip at the ends, apply a small section of gasket to the rear of the backing strip. This will be forced into the recess and seal the end of the strip. AlternativelyuseSikaflex-11FCtofillthegroove.

FIG 23: Sealing Ends of Backing Strip

Panel

Sikaflex-11FCadhesive

Backing Strip


10mm wide x 18mm long strip of Horizontal Gasket

Panel

Sikaflex-11FC

Backing Strip

Panel



PANEL INSTALLATIoN Panels must be in a dry condition when fixed. If panels become wet after installation, allow to dry before covering screw heads.

Panels must only be fixed using Cemintel ExpressWall™ Screws.BareStone™ panels must only be fixed using ExposedHeadScrews.

Installing panels is a three step process:

1.InstallVerticalGasketstoExpressWall™TopHats.2. Screw fix Panel to top hats.3. Cover fastener heads (when using countersunk head

screws).

CSR recommends the use of torque control screw guns.

If it is necessary to remove and replace a panel, avoid reusing screw holes in the top hats by adjusting fixing locations in the panel.

INSTALLING VERTICAL GASKETInst all vertical gasket to central section of the ExpressWall™ TopHatforthefullextentofpanels.Becarefulnottostretchthe gasket when installing. When joining gasket, cut ends cleanly and push together before adhering.

FIG 24: Vertical Gasket Installation

When top hat is discontinuous, butt ends together tightly and continue gasket over the joint. If a gap is present, install a steel strip to support the gasket.

FIG 25: Gasket Support at Discontinuous Joint (0.75 Top Hat shown)

FIXING PANELS USING COUNTERSUNK HEAD FASTENERSDrive the countersunk head screw into the top hat using an electric screw gun. CSR recommends the use of a screw gun with torque control to prevent overdriving of screws.

FIG 26: Fixing with Countersunk Screws to Top Hat 0.75


ExpressWall Vertical Gasket applied centrally on top hat


ExpressWall Vertical Gasket applied centrally in recess



ExpressPanel

30mm

Class 3 finish



ExpressPanel

30mm

Class 3 finish

Steelstrip

10mm max.


PANEL FIXING USING EXPOSED HEAD FASTENERSInstall the ExpressWall™ Weather Seal into the pre‑drilled hole in the panel. Drive the exposed head screw through the weather seal and into the top hat using an electric screw gun. CSR recommends the use of a screw gun with torque control to prevent overdriving of screws.

Exposedheadscrewscanonlybeusedwith1.15BMT top hats as screws can strip in the lighter gauge.

FIG 27: Fixing with Exposed Head Screws

JOINTSPanelsaregenerallyinstalledwithanominal10mmwidth,horizontal and vertical expressed joints between adjacent panels.Jointsupto20mmnominalwidthcanbeformed,provided additional care is taken during installation to ensure that panel edges cover the joint gaskets by a minimum of 10mm.

FIG 28: Vertical Joint Detail

FIG 29: 10mm Horizontal Joint Detail

FIG 30: 20mm Horizontal Joint Detail


Exposed Head Screw

ExpressWall™ Top Hat 1.15

Weather Seal compressed in

hole and compressed around screw thread

Sealant where required

ExposedHead Screw

ExpressWall Weather Seal

Panel

Pre-drilled hole

Panel

ExpressWall Vertical Gasket 6-20mm

ExpressWall Top Hat

ExpressWall CSK Screw

Horizontal Gasket

Backing Strip

Panel

Panel

45mm*

45mm*

10mm

Horizontal Gasket

Backing Strip

Panel

Panel

45mm

45mm

20mm



For ExpressWall™ systems subjected to design wind pressure inexcessof4.0kPa,orincorrosiveenvironmentsasdetailedinTable1onPage10,allhorizontalandverticaljointsmustbe filled with recommended joint sealant. Sealant is also required where prepainted panels are used. Sealant must be installed in accordance with the manufacturer’s instructions.

FIG 31: Sealed Vertical Joint Detail


Atthebeginningandendofaverticaljoint,suchaswithsheets installed in a half‑bond pattern, continue the vertical gasketpast thehorizontal jointby100mmminimum. Refer to FIG 33.

FIG 33: Vertical Gasket and Fixing Detail for Half-bond Panel Layout

Joint filled with sealant

ExpressWall Top Hat

ExpressWall Screw

ExpressWall Vertical Gasket6-20mm

Panel

Horizontal Gasket

Backing Strip

Panel

Panel

45mm*

45mm*

10-20mm

Joint filled with sealant over Bond-breaker Tape



ExpressWall screws each side of top hat

ExpressWall Top Hat

100mm min.

50mm

Backing Strip

100mm min.


Backing Strip

Screw Spacing (refer Table 5)


SCREW HEAD COVERING FOR COUNTERSUNK SCREWS

Allcountersunkscrewheadsmustbecoveredwithepoxycompound and flush finished with the ExpressPanel™ face.

Epoxy shall be installed in the following manner:• Mixepoxyaccuratelyinaccordancewiththe

packaging/manufacturer’sinstructions.• Immediatelyusemixedepoxy.• Avoidoverfillingholes,andleveloffbeforeepoxy

fully cures.• AthinlayerofCemintel™ External Joint Compound may

be used to achieve a flush finish.

FIG 34: Epoxy Covering of Screw Heads

HINT:Onewayofapplyingepoxyisthrougha20mmholeinthinmetalsheet(0.6mmorless)orothersuitablematerial.This will minimise spill‑over and allow for some shrink back of the epoxy without having to repeat the application.

ExpressWall Screw

Screw head covered with epoxy

Top Hat

ExpressPanel

Thin metal strip or other appropriatematerial

ExpressWall Screw

ExpressPanel

Cover screw head andfill hole with Epoxy


CuRvED FACADESCemintel ExpressPanel™andBareStone™ panels can be curvedtoaminimumradiusof10m.Theframingmustbesetout to a true curve to enhance appearance and avoid over‑stressingthesheetandfixings.MaximumtophatspacingsaretobeinaccordancewithTable6,orcloserifrequiredforwind loads.

TABLE 6: Curved Wall Framing and Facade Panel

Curve Radii(m

MaximumTopHatSpacing(mm)

Panel Width900mm

Panel Width1200mmor

Greater

10m-15m 300* 400*

>15m 450 600

*Provide2additionalfixingspermetretoeachtophat.


CoNSTRuCTIoN DETAILSFIG 35: Deflection Head with Expressed Joint

FIG 36: Deflection Head with Filled Joint

WALL FLASHINGSIn general, flashings shall be designed and installed in accordancewithSAA–HB391997–InstallationCodeforMetalRoofingandWallCladding.Stopendsshallbeincorporatedwithallflashings.Allflashingsaresuppliedbyothers.

TABLE 7: Flashing Upstand

Ultimate Design Wind Pressure (kPa)

FlashingUpstandMinimum (mm)

2.5 150

3.5 200

4.0 250

5.0 300

6.0 350

7.0 400

FIG 37: Base Detail for Inline Slab

FIG 38: Base Detail Corrosivity Category D - Inline Slabt

Angle fixed to Top Hat

Sarking

Drip groove Soffit

Backing Rod

Panel

Top Hat

Deflection gap to be specified by project engineer

Support Framing

Continuous bead of sealant between sheet and angle

Sealant depth 12mm min. or 50% of gap height

Concrete footing

Sealant

Sarking

Flashing

Flashing Tape

Panel

Open joint to allow moisture to escape

Flashing upstand (refer to Table)

ExpressWall Top Hat

Steel Frame

Girt Supports to Engineers Details


Drip groove

Soffit

Backing Rod

Panel

Top Hat


Support Framing


Sarking


Concrete footing

Sealant

Sarking

Flashing

Flashing Tape

Panel

100mm max.



ExpressWall Top Hat

Cemintel™ Cavity Baffle

Steel Frame



Sarking

Drip groove Soffit

Backing Rod

Panel

Top Hat


Support Framing



Concrete footing

Sealant

Sarking

Flashing

Flashing Tape

Panel



ExpressWall Top Hat

Steel Frame



Drip groove

Soffit

Backing Rod

Panel

Top Hat


Support Framing


Sarking


Concrete footing

Sealant

Sarking

Flashing

Flashing Tape

Panel

100mm max.



ExpressWall Top Hat


Steel Frame



Sarking

Drip groove Soffit

Backing Rod

Panel

Top Hat


Support Framing



Concrete footing

Sealant

Sarking

Flashing

Flashing Tape

Panel



ExpressWall Top Hat

Steel Frame



Drip groove

Soffit

Backing Rod

Panel

Top Hat


Support Framing


Sarking


Concrete footing

Sealant

Sarking

Flashing

Flashing Tape

Panel

100mm max.



ExpressWall Top Hat


Steel Frame



Sarking

Drip groove Soffit

Backing Rod

Panel

Top Hat


Support Framing



Concrete footing

Sealant

Sarking

Flashing

Flashing Tape

Panel



ExpressWall Top Hat

Steel Frame



Drip groove

Soffit

Backing Rod

Panel

Top Hat


Support Framing


Sarking


Concrete footing

Sealant

Sarking

Flashing

Flashing Tape

Panel

100mm max.



ExpressWall Top Hat


Steel Frame



FIG 39: Framed Soffit Detail

FIG 40: Abutment Detail – Option 1



Sarking

10mm min.

Sealant

Wall

100mm max.

40mm min.

Backing Rod

Top Hat Continuous bead of sealant

Angle 1mm galvanised steel by others

100mmmax.

10-20mm gap

Panel

Top Hat Angle 1mm galvanised steel by others

Sealant

Wall

Backing Rod

Continuous bead of sealant

Sarking

10-20mm gap

Panel

Sealant

Wall

Backing Rod

Sarking


10-20mm gap

Top Hat Angle 1mm galvanised steel by others

Panel

Panel

Top Hat

Flashing behind tophat(refer to upstand Table)

Soffit lining

100mmMax.

30-50mm

Sarking

Flashing Tape

Soffit Casing Bead


FIG 43: Internal Corner Detail

FIG 44: External Corner Detail


Rigid structure at corners




Top Hat spacing

Top Hat spacing

Sarking

10mm nom.

Panel




Sarking

SarkingContinuous bead of sealant

Top Hat spacing

Top Hat spacingSupport Framing

Support Framing


10mm nom.

Panel

Panel


FIG 45: Curved Corner Detail

FIG 46: Angled Corner Detail

Top Hat fixed to frame to engineer's detail

Support Framing

Support Framing

Sarking

10mm nom.

10mm nom.

Corner panel supplied by others



Sarking

Maximum 50% of Top Hat spacing


Support Framing

Support Framing

Intermediate Tophat

Maximum 50% of Top Hat spacing

Angle 1mm galvanised steel supplied by others

Panel


FIG 47: Capping Detail – Option 1

Parapet capping shall be designed and fastened in accordancewithSAA–HB391997–InstallationCodeforMetalRoofingandWallCladding.Stopendsshallbeincorporated to all flashings.

TABLE 8: Capping Overlap

Ultimate Design WindPressure

(kPa)

MinimumCapping Overlap

(mm)

1.5 50

3.5 100

5.0 150

7.0 200

FIG 50: Vertical Control Joint

FIG 48: Capping Detail – Option 2

FIG 49: Horizontal Control Joint

Cap

ping

ove

rlap

(refe

r to

Tabl

e)

Sarking

30mm min.

Fall

Subframe member

Hardwood support

Top Hat

Clip to suit capping fixed through oversize hole in panel

Panel

Sarking

Fall

Bead of sealant


Subframe member

Hardwood support

Top Hat

Gasket to extend to top of ExpressPanel

Screw fix capping to backing strip over continuous bead of sealant

Panel

Flashing

Top Hat

Sealant

Rivet as required

Rivet as required

Rivet

10mm

10mm overlap Anticipated movement +5mm

Anticipated movement +5mm

10mm 10mm

20mm



Flashing behind top hat(refer to Flashing Upstand Table)

Panel

Panel

Sarking

Fall

Bead of sealant


Subframe member

Hardwood support

Top Hat

Gasket to extend to top of ExpressPanel

Screw fix capping to backing strip over continuous bead of sealant

Panel

Flashing

Top Hat

Sealant

Rivet as required

Rivet as required

Rivet

10mm

10mm overlap Anticipated movement +5mm

Anticipated movement +5mm

10mm 10mm

20mm



Flashing behind top hat(refer to Flashing Upstand Table)

Panel

Panel

Movement joint in structure to engineer's specifications

.xam mm001 .xam mm00110-20mm nom. joint


Sealant Top Hat Top Hat Continuous bead of sealant

Galvanised steel angles Backing Rod

Panel Panel


FIG 51: Window Head Detail

FIG 52: Window Sill Detail

Panel

Flashing (refer to Flashing Upstand Table)

NOTE: Use Cavity Baffle in Corrosivity Category C4

Flashing Tape

Gap to allow water to drain over flashing


Sarking

Air seal

ExpressWall Top Hat

Window Frame

Support Framing

Support Framing

Window Frame

ExpressWall Top Hat


Sarking

Air seal

Panel


FIG 53: Window Jamb Detail Option 1



Continuous bead of sealant10mm nom.

Sealant 10mm depth Flashing

SarkingBacking Rod

Air Seal

Window Frame

Panel

Panel

Sarking


Flashing10mm nom.

Air Seal

Window Frame


10mm nom.


Sealant 10mm depth Flashing

SarkingBacking Rod

Air Seal

Window Frame

Panel


WINDOW FLASHING PROCEDUREThe installation of window flashings will depend on the chosen windows and framing methods. The following details show a typical installation procedure.

FIG 56: Typical Window Flashing Procedure

ExpressWall Tophat

Framing

Window frame

STEP 1Install Metal Head Flashing(refer to Flashing Upstand Table)

STEP 2 Install continuous bead of sealant

Continuous bead of sealant behind flashing

Window frame

STEP 7Fill joint with sealant

STEP 6Install Backing Rod

Window frame

STEP 9Install continuousbead of sealant

STEP 8Install ExpressWallVertical Gasket

STEP 10Install Panel

Window frame

Window frame

STEP 3Install Metal Flashing(refer to FlashingUpstand Table)

Window frame

STEP 5Install Metal Flashing

STEP 4Install Intermediate Tophat


FIRE RATED WALL SySTEMSCemintel ExpressWall™ can be used with a variety of CSR Gyprock and Fibre Cement fire rated wall systems.

These can provide a fire rating from one or both sides of the wall depending upon the internal lining materials chosen.

FRL

– / – / –

CSR 933

Rw 25

External Side of Wall Framing

•1layerCemintelExpressPanel™orBareStone™ panels fixed to Cemintel ExpressWall™ top hatframing system.

•Sarking. Internal Side of Wall Framing

•Nil.

WALLWIDTH(excludingwallframe)mm 44

FRL60/60/60

fromoutside of the wall

only

report/opinion

FAr 2357

CSR 934

Rw 38


•1layerCemintelExpressPanel™orBareStone™ panels fixed to Cemintel ExpressWall™ top hat framing system.

•Sarking.

•2layersx16mmGYPROCKFYRCHEKMRplasterboard fixedtoframingspacedat600mmmaximumcentres.

Internal Side of Wall Framing

•Nil.

WALLWIDTH(excludingwallframe)mm 76

note:For additional fire and acoustic systems, please refer to the csr gyprock Fire & Acoustic Design guide, nºgyp500

Refer to the system tables for detailed information.

For detailed information on fixing fire rated linings, refer to theCSRGyprockFire&AcousticDesignGuide,NºGYP500.


FRL60/60/60


only

report/opinion

FAr 2357

CSR 935

Rw 41 – 48



•Sarking.

•1layerx16mmGYPROCKFYRCHEKMR plasterboard fixed to framing.

•Steelstudframingasrequired.


•1layerx16mmGYPROCKFYRCHEK plasterboard fixed to framing.

STUDDEPTH

92 150

CAVITYINFILL Rw

(a)Nil 41 44

(b)R1.5BradfordGoldBatts 46 48

(c)ASB4/TSB4PolyesterBatts 46 48

WALLWIDTHmm 168 226

FRL60/60/60


only

report/opinion

FAr 2303

CSR 905

Rw 41 – 46



•Sarking.

•1layerx16mmGYPROCKFYRCHEKMRplasterboard fixed to framing.

•Timberstudframingasrequired.


•1layerx10mmGYPROCKplasterboardCDfixedtoframing.

STUDDEPTH

92

CAVITYINFILL Rw

(a)Nil 41

(b)R1.5BradfordGoldBatts 46

(c)ASB4/TSB4PolyesterBatts 45

WALLWIDTHmm 160

note: *load limits Apply For additional fire and acoustic systems, please refer to the csr gyprock Fire & Acoustic Design guide, nºgyp500.


FIG 57: Typical ExpressWall™ Fire Rated Installation. (FRL 60/60/60 from outside only)

2 x 16mm Gyprock Fyrchek MR Plasterboard

Refer to Capping Details

Concrete slab

ExpressPanel™ or BareStone™

Sarking

Ground clearance to regulatory requirements

Gyprock Fire Mastic to depth of outer plasterboard layer

Gyprock Fire Mastic to depth of outer plasterboard layer

Top Hat

Roofing

Angle (50 x 50 x 0.75mm BMT gal MS) mechanically fastened to concrete at 600mm max. centres and seal to slab

Refer to base flashing detail

Sarking


FIG 58: Typical ExpressWall™ Fire Rated Installation (FRL 60/60/60 from outside only).

16mm GYPROCK FYRCHEK MR Plasterboard

Non-combustible eaves lining (eg. CSR Fibre Cement Eaves Lining Sheet)

CSR Bradford Fibertex Rockwool

Timber blocking (45mm min. thickness) to form fire barrier

10mm GYPROCK plasterboard CD

10mm GYPROCK plasterboard CD

Concrete slab

ExpressPanel™ or BareStone™

Sarking

Top Hat

Control joint in ExpressWall (refer to detail)

Control joint in plasterboard (15mm high) filled with Gyprock Fire Mastic

Ground clearance to regulatory requirements

Refer to base flashing detail

Gyprock Fire Mastic


ARCHITECTuRAL SPECIFICATIoN

SCOPEThe contractor shall furnish all materials, labour and equipment for the installation of the Cemintel ExpressWall™ Systemwhereindicatedonthedrawingsand/orasspecified.

The ExpressWall™ system shall be installed in accordance withCSRguideNºFC126CemintelExpressWall™.

CLADDING MATERIALSCladding material shall be Cemintel ExpressPanel™ or CeminSealBareStone™ Panel as manufactured by CSR.

ExpressPanel™ shall be 9mm compressed cellulose reinforcedsheetmanufacturedinaccordancewithAS/NZS2908.2.BackfaceissealedwithVC-9,aUVcuredhighbuildclearsealerappliedtoathicknessof35-40µm.FrontfaceofpanelsisundercoatedwithVC-7,aUVcuredhighbuildwhitesealerappliedtoathicknessof35-40µm.FinalcoatisVP-200whiteIntercoatprimerwithathicknessof5-10µmto front face and edges.

CeminSealBareStone™ Panel shall be 9mm compressed cellulose reinforced sheet, incorporating waterblock technology,manufacturedinaccordancewithAS/NZS2908.2.

EXPRESSWALL™ STEEL FRAMINGCeminte l ExpressWal l™ steel f raming system shal l be Cemintel ExpressWall™ TopHat of....................... BMTassuppliedbyCSR,andIntermediateTopHatasmanufacturedbyRondoBuildingServicesPtyLtd.FramingshallbeinstalledinaccordancewithCSRguideNºFC126Cemintel ExpressWall™.

SARKINGSarkingmaterialshallbe*Bradford....................................... ...................................................or product of equivalent or better performance).

CAVITY INFILL INSULATIONCavityinfillshallbe*Bradford...................................(orproductof equivalent or better performance).

FLASHINGSFlashings not supplied by CSR shall be designed and installedinaccordancewithSAA–HB39,1997,InstallationCodeforMetalRoofingandWallCladding.Flashingtobecolour matched to the panels.

FIXINGSScrews for f ixing ExpressPanel™ to top hats shall be ExpressWallCountersunkHeadScrews,Class3finishassuppliedbyCSR.AllcountersunkheadscrewsintheExpressPanel™‚shallbecoveredwith*.....................epoxy,and sanded flush with the panel surface.

OR

Screws for fixing ExpressPanel™/BareStone™ Panel to tophatsshallbeExpressWallExposedHeadScrews, *Class3 f inish/*StainlessSteelassuppliedbyCSR.ExpressWall™ Weather Seal shall be used with all exposed headscrews.*Exposedheadscrewsshallbecolourmatchedto the panels.

ACCESSORIESTapes, gaskets, sealants, backing strips and the like shall be asdetailedinCSRguideNºFC126CemintelExpressWall™.

COATINGSExpressPanel™/BareStone™ Panels shall be coated with *..........................,colour*.......................,whichshallbeinstalledto the manufacturer’s recommendations.

FIRE RATED WALL SYSTEMThe contractor shal l supply and instal l wall system *NºCSR...............inaccordancewithCSRGyprockFire&AcousticDesignGuide,NºGYP500.ThewallshallhaveaFireResistanceLevel*FRL...../...../.....inaccordancewiththerequirementsofAS1530.4.Installationshallalsobecarriedout to the level specified for an acoustic performance of *Rw...........usingcavityinfillof*Bradford...............................

FRAMING, FIXING & JOINTS.AllExpressWall™ framing, fixing and joints shall be designed and installed to comply with the requirements for an Ultimate DesignWindPressureof*............kPaminimum.

note: *insert or select appropriate product/information.


MATERIAL PRoPERTIES

FIRE RESISTANCEUndertheBuildingCodeofAustralia,ClauseC1.12(d),Cemintel™ fibre cement is deemed to be non‑combustible. WhentestedinaccordancewithAS1530.3,theEarlyFireHazardIndicesareasfollows:

ExpressPanel™ & BareStone™ Manufacturing Tolerances

Length +0to-2mm.

Width +0to-2mm.

Thickness +10%to-0%.

Diagonals Difference (max) 2mm

Edge Straightness deviation (max 1mm

Physical Properties

Property

Cemintel™ Compressed Sheet

atEMC* Saturated

Thickness 1700 1900

Flexural Strength (characteristic)

Parallel to sheet length

-ultimate(MPa)2520

-yield(MPa)2013

Parallel to sheet width

-ultimate(MPa)2016

-yield(MPa)

25

20

20

17

20

13

16

12

ModulusofElasticity(GPa) 10 9

Thermal Expansion Coefficient 10x10-6/K° (est. average)

MoistureMovement

-fromEMC*tosaturated

-from30to90%RH (toASTMC1185)

-700Microstrains (expansion)

-500Microstrains (expansion)

note: * emc (equilibrium moisture content) is at nominally w23°c and 50% relative Humidity environment conditions.

FIRE RESISTANCEUndertheBuildingCodeofAustralia,ClauseC1.12(d),Cemintel™ fibre cement is deemed to be non‑combustible. WhentestedinaccordancewithAS1530.3,theEarlyFireHazardIndicesareasfollows:

SYSTEM TESTINGThe Cemintel ExpressWall™ System has been designed and tested by CSR Gyprock & Fibre Cement Research & Development. The ExpressWall™ System has passed testingtothefollowingpartsofAS/NZS4284-1995TestingofBuildingFacades.

•StructuralTest.•WaterPenetrationbyStaticPressure.•WaterPenetrationbyCyclicPressure.•ProofTest.

ThesystemhasbeentestedtoAS4040.3-1992Methodsoftestingroofandwallcladding,Method3:Resistancetowindpressure for cyclonic regions.


HANDLINg & SToRAgEAllCemintelExpressPanel™andBareStone™ panels must be stacked flat, clear of the ground, and supported on a level platform.

Care must be taken to avoid damage to edges, ends and surfaces.

Materialmustbekeptdry,preferablybybeingstoredinside the building. Protect from contaminants such as silicone spray.

Where it is necessary to store panels outside, they must be protected from the weather.

Panels must be dry prior to fixing and finishing.

SAFETyWhen cutting panels using power tools, always ensure the workareaiswellventilated.Anapproveddustmask(AS1715andAS1716)andsafetyglasses(AS1337)mustbeworn.CSRrecommends that hearing protection be worn.

PANEL CuTTINg

POWER SAWWhen it is necessary to use power tools for cutting panels, CSRrecommendsusingtheHitachiFibreCementPowerSawBlade.Thisbladeisspecificallydesignedforusewithfibre cement and produces a superior cut compared to conventional blades.

ItisidealforusewiththeHitachiC7YAdustlesscircularsawandother185mmcircularsawsfittedwithvacuumextractionsystems.

DRILLINGCountersunk holes in Cemintel ExpressPanel™ shall be drilled and countersunk with the recommended countersinking tool. Allgeneralpurposedrillingofpanelsshallbedonewithamasonry drill bit.

note: in all cases Do not use hammer action when drilling.

Hitachi c7yA Dustless circular saw with Dust extraction system.

Hitachi Fibre cement power saw Blade.

EXPRESSWALL FC:126

CONTACT DETAILS

www.CEmINTEL.COm.Au

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HealtH & Safety

WaRNINGFibre Cement products contain crystalline silica. Repeated inhalation of fibre cement dust may cause lung scarring (silicosis) or cancer. Do not breathe the dust. When cutting sheets, use the methods recommended in this brochure to minimise dust generation. If power tools are used, wear an approved dust mask (respirator). These precautions are not necessary when stacking, unloading or handling fibre cement products.

For furtherinformation and for a Material Safety Data Sheet, phone 1800 807 668.

GuaRaNteeCSR Building Products Limited (“CSR”) warrants its Cemintel ExpressPanel™ and Barestone™ panels (“Product”) to remain free of defects in material and manufacture for 10 years from date of purchase.

In the event of any failure of the Product caused by the direct result of a defect in the material or manufacture of the Product, CSR will at its option replace or repair, supply an equivalent product, or pay for doing one of these.

This warranty does not apply where the Product has been used in any manner not in accordance with the manufacturer’s instructions, nor the reuse of the Product after its initial installation. CSR recommends that only those products, components and systems recommended by it be used. CSR wil l need to be satisfied that any defect in its Product is attributable to material or manufacture defect (and not another cause) before this warranty applies.

Other than as expressly set out in this warranty, and the guarantees that cannot be excluded under The Australian Consumer Law (Schedule 2 of the Competition and Consumer Act 2010 (Cth)) (and any other law), CSR excludes all other warranties and guarantees with regard to the Product including all guarantees and warranties that may apply at law.

To the extent that it is able to do so, CSR excludes all liability for loss and damage (including consequential loss) in connection with the Product. This exclusion does not apply where the Product is sold to a consumer and is a good of a kind ordinarily acquired for personal, domestic or household use or consumption.

The following statement is provided where the Product is supplied to a buyer who is a “consumer” under the Australian Consumer Law: Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure. The benefits of this warranty are in addition to other rights or remedies of the consumer under law in relation to the goods or services to which the warranty relates.

Notification of a warranty claim must be made to CSR prior to any return of the Product.

To make a claim under this warranty, you must contact CSR on 1300 CEMINTEL. All expense of claiming the warranty will be borne by the person making the claim. CSR may require documentation supporting the claim to be provided.

AuGuST 2012

CSR Cemintel™ Sales Support Tel: 13 17 44 Fax: 1800 646 364

CSR designLINK® Technical Support Service Tel: 1800 621 117

New South Wales and ACT 376 Victoria Street, Wetherill Park NSW 2164

Queensland 768 Boundary Road, Coopers Plains QLD 4108

Victoria 277 Whitehall Street, Yarraville VIC 3013

South Australia Lot 100 Sharp Court, Mawson Lakes SA 5095

Western Australia 21 Sheffield Road, Welshpool WA 6106

Tasmania PO Box 61, Glenorchy TAS 7010

Northern Territory Cnr Stuart Hwy & Angliss St, Berrimah NT 0828

Cemintel™, ExpressWall™, ExpressPanel™, BareStone™ & CeminSeal™ are trademarks of CSR Limited.

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