rockcote solid walling systems...rockcote solid walling systems are built on over 20 years...
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ROCKCOTE SOLID WALLING SYSTEMS THERMAL: FACE FIXED
THERMAL: CAVITY
IMPACT: FACE FIXED
IMPACT: CAVITY
FIRE ZONE
IMPORTANT INFORMATION The Rockcote Solid Walling Systems are complete systems and must be installed as such:
• Strictly in accordance with the relevant Rockcote Solid Walling System Specifications
• By experienced installers who have the relevant skills and trade qualifications, and after proper detailing and integration with the
other components of construction by a qualified design and construction professional
All components, including the Rockcote Solid EPS Base Board, EPS Batten, ROCKCOTE PM100, ROCKCOTE reinforcing mesh, ROCKCOTE
texture coatings, paint and all ancillaries form part of and are critical to the performance of the system. Any substitution of non-compliant parts or
materials could compromise the performance of the system and would nullify the warranty.
All components for the Rockcote Solid Walling System, except for the EPS Wall Panels, Fix n Foam and SikaFlex can be obtained from Rockcote.
For full particulars of the Rockcote Solid Warranty and Stockists of the Rockcote on 1300 736 668.
BEFORE INSTALLATION PLEASE READ THE FOLLOWING DISCLAIMER CAREFULLY DISCLAIMER
This manual provides, in good faith, information on the correct procedures and materials to be used for the installation of the Rockcote Solid
Walling System over framed and solid structures. The drawings and details are to assist design and construction professionals (Specifiers,
Architects, Building Designers & Engineers, Builders, Applicators and Installers) in the correct design, detailing and installation of the System. It is
impossible to cover every possible application of the Rockcote Solid Walling Systems within this manual. Specific design, detailing and installation
must be undertaken by the appropriately qualified and experienced design and construction professionals, who will be responsible for ensuring
that the Rockcote Solid Walling System and the information and details in this manual are suitable for any intended design and application. Used
in that context, the Rockcote Solid Walling Systems are a complete system. ROCKCOTE Enterprises Pty Ltd will not accept responsibility for its
Systems where they are misused or not installed and maintained in complete accordance with ROCKCOTE’s installation, maintenance and
technical recommendations.
No part of this manual may be reproduced, transmitted or translated in any language in any form, by any means, without the prior written permission
of ROCKCOTE Enterprises Pty Ltd.
Copyright (c) 2012 ROCKCOTE Enterprises Pty Ltd. All rights reserved.
Information provided in this booklet was correct at the
time of printing (13/06/12). For the latest Rockcote System
Guide and product information, visit the Rockcote website
WWW.ROCKCOTE.COM.AU
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GLOSSARY OF TERMS
Installer
Meaning the qualified, experienced and licensed tradesperson who installs and/or supervises the installation of the EPS panels and the application
of the RRR System, as described in the ROCKCOTE Solid Installation Manual and information brochure.
Cladding Installer
Meaning the qualified, experienced and licensed tradesperson who installs the EPS panels, as described in the ROCKCOTE Solid Installation
Manual and information brochure.
Applicator
Meaning the qualified, experienced and licensed tradesperson who applies the PM100, reinforcing mesh and ROCKCOTE’s range of Acrylic
Coloured Renders, as described in the ROCKCOTE Solid Installation Manual and information brochure.
ROCKCOTE Solid Top Coats
Meaning ROCKCOTE’s Armour Flex, Armour Plus, Clearcote and Repel range of membranes and sealers applied as per ROCKCOTE’s
specifications.
Building Designer/Construction Professional
Meaning a suitably qualified, registered building designer licensed to carry out the design and specification of building work.
EPS Wall Panels
Meaning expanded polystyrene panels made from M grade polystyrene manufactured to AS 1366.3-1992, containing both an insect repellent and
flame retardant.
EPS Battens
Meaning expanded polystyrene battens made from H grade polystyrene manufactured to AS 1366.3-1992, containing both an insect repellent and
flame retardant.
ROCKCOTE
Meaning ROCKCOTE Enterprises Pty Ltd ABN 42 066 227 174
ROCKCOTE SOLID WALLING SYSTEM
Meaning the walling system comprising of the specified panels installed and coated with the RRR System, as described in the relevant manual and
information brochure.
RRR System
Meaning the ROCKCOTE Reinforced Render System as described in the relevant manual and information brochure.
Specifier
Meaning a person trained, qualified and licensed to carry out the design and specification of building work.
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Table of Contents GLOSSARY OF TERMS ........................................................................................................................................................ 2
INTRODUCTION ................................................................................................................................................................. 5
1.0 ONE SYSTEM—MANY BENEFITS ............................................................................................................................ 7
1.01 Components ................................................................................................................................................ 7
1.02 User benefits ............................................................................................................................................. 12
2.0 RRR COATING SYSTEM ........................................................................................................................................ 14
2.01 General ...................................................................................................................................................... 14
2.02 Critical factors ........................................................................................................................................... 14
2.03 Applicator ................................................................................................................................................... 14
2.04 Pre-coating system inspection ............................................................................................................... 14
2.06 Fitting PVC angle beads .......................................................................................................................... 15
2.07 Reinforced render installation ................................................................................................................. 15
2.08 Curing ......................................................................................................................................................... 15
2.09 Fibreglass mesh ....................................................................................................................................... 15
2.10 ROCKCOTE flexible acrylic-based texture coating ............................................................................. 16
2.11 Health and safety ...................................................................................................................................... 16
3.0 REPAIR AND MAINTENANCE ............................................................................................................................... 17
3.01 Cleaning ..................................................................................................................................................... 17
3.02 Maintenance inspection ........................................................................................................................... 17
3.03 Repair ......................................................................................................................................................... 17
4.0 PRODUCT INFORMATION .................................................................................................................................... 18
4.01 Product support ........................................................................................................................................ 18
4.02 Warranty .................................................................................................................................................... 18
5.0 DESIGN CONSIDERATIONS .................................................................................................................................. 19
5.01 General ...................................................................................................................................................... 19
5.02 Structure .................................................................................................................................................... 19
5.03 Rockcote Solid-EPS Cavity walling panel and batten sizes .............................................................. 19
5.04 Curved walls .............................................................................................................................................. 19
5.05 Wind zones ................................................................................................................................................ 19
5.06 Limitations.................................................................................................................................................. 19
5.07 Insulation values ....................................................................................................................................... 20
5.08 Acoustic values ......................................................................................................................................... 20
5.09 Impact resistance ..................................................................................................................................... 20
5.10 Serviceable life.......................................................................................................................................... 20
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5.11 Maintenance .............................................................................................................................................. 20
5.12 Moisture ..................................................................................................................................................... 20
5.14 Fire .............................................................................................................................................................. 21
5.15 Non-hazardous material .......................................................................................................................... 21
6.0 INSTALLATION AND FIXING ................................................................................................................................. 22
6.01 Timber and steel wall framing ................................................................................................................ 22
6.02 Cutting and drilling .................................................................................................................................... 22
6.03 Beads ......................................................................................................................................................... 22
6.04 Expansion joints........................................................................................................................................ 23
6.05 Concrete and masonry walls .................................................................................................................. 23
6.06 Handling and storage ............................................................................................................................... 23
6.07 Health and safety ...................................................................................................................................... 23
7.0 CONSTRUCTION DETAILS .................................................................................................................................... 25
7.01 Panel fixing ................................................................................................................................................ 25
7.04 Termites ..................................................................................................................................................... 25
7.05 Slab on ground.......................................................................................................................................... 25
7.06 Timber floor First floor / Horizontal Control Joint Details .................................................................... 26
7.7 Wall to roof ................................................................................................................................................ 26
7.8 Parapets ..................................................................................................................................................... 26
7.9 Soffit and eaves ........................................................................................................................................ 26
7.10 Doors .......................................................................................................................................................... 26
7.11 Windows .................................................................................................................................................... 26
7.16 Decorative mouldings .............................................................................................................................. 26
8.0 FINISHING ............................................................................................................................................................ 28
8.01 Sleeve ........................................................................................................................................................ 28
8.02 Penetrations .............................................................................................................................................. 28
8.03 Fixtures ...................................................................................................................................................... 28
8.04 Sealants ..................................................................................................................................................... 28
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INTRODUCTION The information in this manual is compiled for use by the building designer/construction professional and any user
of the Rockcote Solid Walling System – EPS Cavity, to assist in developing project specifications and to provide
guidance on the correct installation of the Rockcote Solid Walling System – EPS Cavity in domestic applications.
The Rockcote Solid Walling System – EPS Cavity consists of specified EPS panels, EPS battens polymer modified
cement render, reinforcing mesh, flexible, acrylic-based texture coating and high film build acrylic top coat. This
system forms a barrier wall with cavity, which is intended to resist the ingress of water from the exterior surface
of the building. The cavity is present to provide a back-up to drain any water from leaks or condensation from
behind the wall.
Correct detailing and integration with the other components of the building by a qualified building designer is
essential. All details and flashings must prevent moisture accumulating behind the wall and direct water to the
outside of the system.
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From being named UDIA Champion Project for Sustainable Development in 2002 to finalist in the prestigious
international FIABCI Prix D’Excellence Awards in 2008, The ROCKCOTE Design Centre has been winning acclaim since
it was first sketched out on the drawing board.
At ROCKCOTE we believe the honour is not in winning awards but in deserving them.
The protruding office area features 60mm polystyrene on timber studs. Main wall areas are tilt up reinforced
concrete with 40mm polystyrene exterior facing bonded to the wall when poured. The excellent insulation of the
RRR system and high thermal mass of the masonry allows this building to remain comfortable year-round without
artificial heating or air conditioning.
Energy efficient design and construction delivers houses and buildings that are more comfortable to live in and
cheaper to run. Insulation acts to keep out heat in summer and to keep heat in during winter. See section 5.07.
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1.0 ONE SYSTEM—MANY BENEFITS Rockcote Solid Walling Systems offer insulative systems that delivers the look and feel of masonry—a
genuinely seamless rendered finish for lightweight energy efficient walls. Offering design freedom, flexibility
and long-term durability, the system’s performance has been proven in conditions ranging from the extreme
cold of alpine regions, to the humidity of the tropics.
The EPS Cavity system can be fitted over standard timber and steel stud walls, and is also suitable for use over
concrete or masonry walls, where they provide an insulating barrier, allowing the thermal mass of the masonry
to help moderate indoor temperatures.
The EPS Cavity system incorporates the installation of a 25mm drainage cavity. This gives additional moisture
protection and a higher Insulative rating over the Face Fix system.
1.01 Components
1.01.01 EPS Battens
H grade polystyrene conforming to AS 1366.3-1992, containing flame retardant additives. The
standard thickness of the batten is 25mm and is supplied in lengths of 1.2m.
1.01.02 Expanded Polystyrene (EPS) board
M grade polystyrene conforming to AS 1366.3-1992, containing both flame retardant and insect
repellent additives. The standard thicknesses are 60 and 75mm, supplied in standard sheet sizes of
1.2 x 2.5m and 1.2 x 5.0m.
1.01.03 Fixings
See relevant Wind Loadings in Section 5.05 for fixing centres.
Timber Framing
NOTE: All timber screws must have at least 25mm of screw shaft screwed into the timber frame.
Fix 60mm EPS Wall Panels with 10-8 x 115mm Buildex Climacoat 3 CSK Ribbed Head Class 3 screws.
Fix 75mm EPS Wall Panels with 10-8 x 125mm Buildex Climacoat 3 CSK Ribbed Head Class 3
screws .
Washers for both are 10 x 40mm grey nylon.
Steel Framing
Fix 60mm RRR-EPS Wall Panels with Buildex 115mm Countersunk Steel Self Drilling 6-311-0621-
1MP screws.
Fix 75mm RRR-EPS Wall Panels with Buildex 125mm Countersunk Steel Self Drilling 6-311-0622-
2MP screws.
Washers for both are 10 x 40mm grey nylon.
1.01.04 Render Trims
ROCKCOTE has developed a range of trims designed specifically for each ROCKCOTE Solid Walling
System.
ROCKCOTE Solid Starter Trims: Use on foundations and roof awning apron.
• 75mm Starter Trim Code: 2641
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• 100mm Starter Trim Code: 2772
Figure 1.01.03a ROCKCOTE Solid Starter Trims.
ROCKCOTE Solid Control Joint Trims: Used for all control joints and internal corners
• 60mm Control Joint Trim Code: 2211
• 75mm Control Joint Trim Code: 1799
Figure 1.01.03b ROCKCOTE Solid Control Joint Trims.
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ROCKCOTE Solid Pre-Meshed Trim Code: 4049
• Pre-Meshed Trim for reveals and external corners
Figure 1.01.03c - ROCKCOTE Pre-meshed Trims.
Rockcote Solid Walling Systems are built on over 20 years experience, and each component has been
specifically designed or selected to meet strict criteria.
All components, including the EPS base board, EPS Batten, ROCKCOTE PM100, ROCKCOTE
reinforcing mesh, ROCKCOTE texture coatings, paint and all ancillaries form part of and are critical to the
performance of the system. Any substitution of non-compliant parts or materials could compromise the
performance of the system and would nullify the warranty.
1.01.04 ROCKCOTE Patch n Prep
Cement based Adhesive with a high Polymer addition. Rockcote Patch n Prep must be used to
fasten both Control Joint and Pre-meshed Trims. Figure 1.01.02d ROCKCOTE Solid Pre-Meshed Trim.
1.01.05 ROCKCOTE PM100
Polymer modified cement renders specifically designed to be applied easily and adhere to EPS
base board.
1.01.06 Reinforcing mesh
Alkali resistant fibreglass mesh, 4.5mm weave, 160 g/m2. This is a critical component and
cannot be substituted without affecting the performance of the system. Only ROCKCOTE
fibreglass mesh may be used under the system warranty.
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Figure 1.01.05a - ROCKCOTE MESH.
1.01.07 Coloured Render, Textures, Protective Finishes
All Rockcote Solid walling Systems are designed to be finished with at least 1mm of dry film
thickness of ROCKCOTE acrylic-based coloured render or texture, plus an optional acrylic
ROCKCOTE paint or sealer.
1.01.08 Colour
Rockcote acrylic textures and paints are available in a wide range of colours and textures.
However, the selection of dark colours on external walls exposed to direct sunlight can lead to
excessive heat build-up in the wall, as the heat is trapped by the insulation underneath and
could possibly cause a breakdown of the coating system. Only colours with a Light Reflectance
Value [LRV] over 40% can be used on the standard ROCKCOTE SOLID EPS Systems.
If a colour darker than 40% is required then contact Rockcote for a specific coating system
specification to meet requirements.
1.01.09 Specialised tools and plastering machines
ROCKCOTE has continually improved application efficiencies and finish standards through its
introduction of specialist tools, mixing apparatus and plastering machines.
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Other components required are:
Fix N Foam
SikaFlex
Vapour permeable building wrap
These can be bought from your local distributor. Please contact Rockcote on 1300 736 668 if
you would like further information.
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1.02 User benefits
1.02.01 Excellent thermal insulation
The external location of the RRR- EPS Walling places the insulation in the best position, as far
towards the outside of the building as possible, where the temperature fluctuates. This reduces
the amount of energy required to maintain a constant temperature inside. Furthermore, the
insulation performance of EPS does not deteriorate during its lifetime.
The incorporation of a cavity further improves the overall insulation (R-Value) of the wall.
1.02.02 Biologically inert
EPS is an inert organic material that will not rot and is highly resistant to mildew. It does not
degrade into harmful substances, is not water soluble and does not give off any water soluble
substances, which contaminate ground water.
1.02.03 Insect resistant
EPS provides no nutritive value to ants, termites or rodents. Only suitably treated EPS Boards
must be used.
1.02.04 Flame retardant
EPS panels are manufactured to AS 1366.3-1992, containing fire retardant additives.
1.02.05 Cost effective
The EPS System offers an attractive, cost efficient, insulative walling system.
1.02.06 Production
EPS Walling uses far less energy in its manufacture than conventional building materials.
1.02.07 Easy to install
EPS Walling is light, practical, safe, easy to handle and install.
1.02.08 Level 5 Finish
Due to a number of factors the Rockcote Solid Walling system can achieve a level 5 finish, with
the look and feel of masonry. Visible board joints and wavy walls under critical light are a thing
of the past.
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Levels of finish for light
weight claddings to
external walls
System Characteristics
and finish
LEVEL 1:
CEMENT SHEET
Expressed joints.
Standard paint finish.
Visible PVC sheet
joiners.
Painted flat finish.
Will follow the frame
straightness.
LEVEL 2:
CEMENT SHEET
Joints taped and patched.
Roll-on texture coating.
Joints may be visible
under side-light
conditions.
Not recommended for
broad wall installation on
quality projects.
LEVEL 3:
CEMENT SHEET
Joints taped and patched.
2mm trowel-on texture
coating or polymer render.
Joints may be visible
under side-light
conditions (critical light).
Not recommended for
broad wall installation on
quality projects.
LEVEL 4:
CEMENT SHEET
Joint taped and set.
Polymer render over entire
wall.
Joints may be visible
under side-light
conditions (critical light).
Not recommended for
broad wall installation on
quality projects.
LEVEL 4:
POLYSTYRENE RRR40
ROCKCOTE Reinforced
Render System for
lightweight claddings.
RRR EPS 40mm
Finished with
ROCKCOTE Reinforced
Render System.
Continuous render finish.
Joints not visible under
normal lighting
conditions.
May be some evidence of
studs or panel joints
under severe side light.
LEVEL 5:
POLYSTYRENE RRR60 and
POLYSTYRENE RRR75
ROCKCOTE Reinforced
Render System for
lightweight claddings.
RRR EPS 60mm–100mm
No visible joint sunder
any light conditions.
Look and feel of rendered
masonry.
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2.0 RRR COATING SYSTEM
2.01 General
All Rockcote Solid Walling Systems utilise a variation of the Rockcote Reinforced Render (RRR) System
to coat each different base sheet. Each walling system is a complete system in which each component
has been specifically designed or selected to meet strict criteria and is critical to the performance of the
system. The panels and flashing details must be installed in accordance with the project plans and
specifications.
All work must be carried out by suitably qualified tradespeople with experience in this area.
The RRR coating system consists of:
• ROCKCOTE PVC angle beads, starter and edge strips
• ROCKCOTE PM100
• ROCKCOTE 160g/m2 alkali resistant fibreglass reinforcing mesh
• ROCKCOTE flexible acrylic-based texture coating
• ROCKCOTE acrylic paints/sealers.
2.02 Critical factors
• The thickness of the full RRR coating system including the render should not exceed 8mm unless
otherwise specified.
• The ROCKCOTE PM100 must be properly cured.
• The correct grade and quality of fibreglass reinforcing mesh must be used.
• The reinforcing mesh must be correctly installed just below the exterior surface of the render.
• The top coat must include at least 1mm dry film thickness of ROCKCOTE acrylic-based Coloured
Render coating or polymer render, plus an optional membrane or sealer dependant on selected finish.
• The colour chosen shall have a LRV (Light Reflectance Value) greater than 40% for the standard RRR
coating system. For colours with a lower LRV a specialised coating system can be recommended by
Rockcote.
2.03 Applicator
Application of the ROCKCOTE Reinforced Render (RRR) System is a specialist procedure and
should only be carried out by an applicator with the relevant trade qualifications and experience.
2.04 Pre-coating system inspection
Ensure that the panels have been fitted in accordance with the project plans and specifications, and that
the substrate is suitable for the application of the RRR System.
• Walls must be clean and dry before rendering can commence
• Check that the walls are straight and all joints are flush
• Check the fixings
• Check that all internal and external corners have been formed correctly and have true lines
• Sand back any irregularities and dust down the wall with a broom or compressed air to remove all dust
and loose material
• Seal around any extrusions through the walls and around windows with a flexible joint filling compound,
as referred to in Sections 8.02 and 8.04.
2.05 Preparation
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Before commencing any rendering work, ensure that the work area is clean and tidy, with a well set up
mixing area, all tools and equipment are clean and any mechanical equipment in good working order with
current safety certification.
Check that all scaffolding is safe, complete and correctly set up for the job.
Ensure that all windows, joinery and finished work adjacent to the work areas are suitably masked and/or
protected, prior to commencing any rendering.
2.06 Fitting PVC angle beads
Beads must be installed straight and true using ROCKCOTE Patch & Prep, allowing for the correct
thickness of finished render.
2.07 Reinforced render installation
Before commencing application, ensure all angles and base beads are correctly fitted, all windows and
adjacent surfaces are masked and the correct scaffolding is in place. Measure and pre-cut reinforcing
mesh.
Install extra 200mm x 400mm reinforcement strips across the resurgent corners of all openings at an
angle of 45º.
Machine application is the preferred method of applying ROCKCOTE PM100, using a plastering machine
capable of mixing and applying between 12–25 litres/minute.
For hand application, mix the render in a suitable container, firstly adding approximately 4 litres of
clean water per 20kg bag of ROCKCOTE PM100. Slowly add the ROCKCOTE PM100 to the water,
while stirring with a mechanical stirrer.
More water or powder may be added to achieve the desired trowelable consistency. Refer to the
ROCKCOTE PM100 Technical Specifications for mixing details.
Using a suitable plastering machine or a hawk and trowel, apply the ROCKCOTE PM100 RENDER to an
area of wall and screed or level the wet render using an H section straight edge or Darby. Avoid
overworking the render, as this can cause moisture build-up on the surface of the substrate, causing the
render to slump or slide.
Using the angle beads as a guide, the render is screeded to the level of the beads to achieve a straight,
flat surface. After allowing the render to ‘firm up’, the ROCKCOTE fibreglass mesh is trowelled into the
surface of the wet render, keeping it just below the surface of the render. When applying the mesh, start
at the top of the wall and work down. Ensure that the mesh overlaps all joints by at least 50mm and
overlaps the outside edge of all beading.
As the wall dries, trowel or float the wall to achieve a straight flat finish suitable for the subsequent
application of the acrylic-based texture coating.
2.08 Curing
ROCKCOTE PM100 is a cement-based product and correct curing procedures must be followed. In hot,
dry, windy conditions, it will be necessary to wet the finished wall down regularly for up to three days.
Render cannot be applied in freezing conditions and uncured material must not be allowed to freeze.
2.09 Fibreglass mesh
The fibreglass mesh (160 gram) is a critical component of the RRR-EPS System and must be correctly
installed.
The mesh is to be trowelled into the surface of the wet render, positioned just below the surface. Under
no circumstances should the mesh be fixed to the walls and render applied over it. Overlap all sheets a
minimum of 50mm and overlap the inside edge of all beading. Install extra reinforcement strips across the
resurgent corners of all openings at an angle of 45º prior to rendering.
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2.10 ROCKCOTE flexible acrylic-based texture coating
The ROCKCOTE flexible texture coating is an integral component of the RRR-EPS System and must be
applied to the specified dry film thickness of at least 1mm.
Application of the texture coating can commence once the render has been cured and is dry.
The texture coating is applied using a stainless steel trowel or suitable spray machine and finished with a
plastic or polystyrene float to the required finish.
The texture coating may be tinted to the required finish colour.
Suitable ROCKCOTE Systems include:
• Santa Fe
• Polyfine
• Sandcote
• Quicksand / Quicksand Coarse
• Acrylic Texture Range (Medium / Coarse)
• 1mm, 2mm or 3mm Trowel-On over-coated with ROCKCOTE Armour
• Polymer Render over-coated with ROCKCOTE Armour
• Polymer Render HB. over-coated with ROCKCOTE Armour
Acrylic top coats from the ROCKCOTE Armour range or the ROCKCOTE Roll-On Texture range can then
be applied to provide added flexibility and durability. This is recommended in areas exposed to severe
weather conditions (i.e. beachfront locations).
2.11 Health and safety
When working with ROCKCOTE Renders, observe the usual precautions for handling cement and water-
based products. Ensure compliance with all Workplace Health and Safety regulations and Industry Codes
of Practice.
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3.0 REPAIR AND MAINTENANCE
3.01 Cleaning
Exterior walls should be cleaned down every twelve months, or as required. Use a biodegradable
detergent to remove any built-up dirt or grime. Wash with a low pressure water cleaner and
environmentally-sensitive cleaning solution, when a major clean is required. Mould or fungus must be
treated with a residual fungicide, Rockcote recommends the use of Rockcote Fungicidal wash which has
been specifically designed for this purpose.
Refer to the ROCKCOTE SOLID WALLING System Maintenance Guide for further cleaning and
maintenance information.
3.02 Maintenance inspection
Annual inspection of the exterior walls must be made to ensure they remain in good condition. Checks
must be made of the exterior coating system, sealants, flashings, control joints and any waterproofing
systems. Pay particular attention when inspecting for sealant deterioration.
3.03 Repair
Immediately repair damaged areas or cracks to prevent water penetration. Repair damaged areas with
ROCKCOTE Reinforced Render (if required). Fill cracks with flexible, external, paintable patching
compound. Repaint the repaired area.
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4.0 PRODUCT INFORMATION
4.01 Product support
ROCKCOTE regularly updates its literature to keep pace with product developments and design trends,
and therefore reserves the right to revise and change its technical information without notice.
4.02 Warranty
4.02.01
The ROCKCOTE SOLID Walling System carries a complete system warranty provided that it is:
• installed as a complete system by experienced installers who have the relevant skills and
trade qualifications
• installed after proper detailing and integration with the other components of construction, by
an appropriately qualified and experienced design and construction professional
• maintained strictly in accordance with the ROCKCOTE SOLID Walling System specifications.
4.02.02
This warranty covers loss arising from defects in the components of the ROCKCOTE SOLID
Walling System (excluding accessories and components manufactured or supplied by an
unrelated third party). Except to the extent imposed by any mandatory Australian law, liability
under this warranty is limited to replacement and/or repair by ROCKCOTE of any defect solely
attributable to defective ROCKCOTE SOLID Walling System components that do not meet
ROCKCOTE’s standards.
4.02.03
ROCKCOTE will not accept responsibility for its systems where they are misused or not
installed and maintained in complete accordance with ROCKCOTE’s installation, maintenance
and technical specifications.
4.02.04
All specified components (including the Wall Panel, ROCKCOTE PM100, ROCKCOTE
reinforcing mesh, ROCKCOTE texture coatings, ROCKCOTE paint or sealers and all specified
ancillaries) form part of, and are critical to the performance of the system.
Any substitution with non-conforming parts or materials could compromise the performance of
the System and will nullify the warranty.
All components for the ROCKCOTE SOLID, except Wall Panels, can be obtained from
ROCKCOTE.
RRR-EPS Wall Panels can be obtained from ROCKCOTE’s nominated suppliers.
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5.0 DESIGN CONSIDERATIONS
5.01 General
The ROCKCOTE SOLID Walling System forms an integrated, seam-free render finish and weather-
resistant thermal envelope to the exterior walls of a building. A properly designed and insulated building can
reduce energy costs by up to 80%. The external location of the EPS puts the insulation in the best position,
as far towards the outside of the building as possible, where temperature fluctuates. This reduces the
amount of energy required to maintain a constant temperature inside and provides higher levels of comfort.
5.02 Structure
All timber and steel framing is required to be framed, braced, trimmed and finished in accordance with best
trade practice and to comply with the requirements of all relevant Australian Standards and Statutory
Authority requirements.
RRR-EPS-60mm and 75mm have sufficient strength and rigidity to be supported by wall framing spaced
at 600mm maximum centres.
When RRR-EPS-40 is used over a timber frame, 450mm stud centres are recommended.
RRR-EPS-40mm can be installed directly over concrete/masonry walls.
5.03 Rockcote Solid-EPS Cavity walling panel and batten sizes
RRR-EPS Standard Wall Panels
2500mm x 1200mm x 60mm
2500mm x 1200mm x 75mm
Wall panels are available in 5.0m lengths upon request.
25mm thick * 40mm wide * 1.2m long H grade EPS battens are available from National Polystyrene.
5.04 Curved walls
40mm and 60mm Wall Panels can be curved to a radius greater than 2.5 metres. Where a tighter radius
is required, multiple layers of specially ordered 20mm thick panels can be used, with the joints offset
between layers. However, special consideration should be given to detailing flashings, angle beads and
the like.
5.05 Wind zones
Properly installed, the RRR-EPS System is suitable for use in the following building wind zones:
Wind Zone/Classification Maximum Fixing Centres
N1 and N2 300mm
N3, C1 200mm
5.06 Limitations
The ROCKCOTE SOLID-EPS Cavity Walling System is not designed to provide structural bracing. If
structural bracing is required, use internal linings or other specifically designed wall bracing.
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ROCKCOTE SOLID-EPS Cavity Walling is not suitable for use in and must be separated from chimneys,
flues or fireplaces.
ROCKCOTE SOLID-EPS Cavity Walling must not come in contact with the ground for extended periods of
time. It cannot be used for retaining walls.
THIS MANUAL IS LIMITED TO DOMESTIC CONSTRUCTION.
Designers and Installers must check that the details in this manual meet their own specific requirements.
5.07 Insulation values
All insulation materials are rated for their performance in restricting heat transfer. This rating is expressed
as an R-value which is the measure of the material’s resistance to heat transfer (thermal resistance). The
higher the R-value, the greater the insulating effect.
60mm EPS Walling 1.6 2.7
75mm EPS Walling 2.0 3.1
** - R-values have been calculated with 10mm plasterboard, 90mm air gap (stud), antiglare foil, 25mm air gap (batten), M-grade EPS and Rockcote
Reinforced Render System (RRR).
5.08 Acoustic values
60mm Rockcote Solid-EPS Cavity System fixed to a 75mm stud frame, lined internally with standard
10mm Gyprock and with either Rockwool or glass fibre wool cavity insulation, will achieve an STC rating
of greater than 50.
5.09 Impact resistance
Properly installed, the Rockcote Solid-EPS Cavity System has sufficient impact resistance for most
domestic situations. In situations where high impacts may occur, then a double layer of ROCKCOTE
Reinforced Render, with double layers of mesh is recommended.
Additional impact resistance can be obtained by using a VH grade EPS board, instead of M grade.
Ensure that the board does contain insect and fire resistant additives.
5.10 Serviceable life
The Rockcote Solid-EPS Cavity System, properly installed and maintained, has an expected serviceable
life of at least 30 years under typical (rather than extreme) Australian conditions.
5.11 Maintenance
Exterior walls should be cleaned down every twelve months. Regular inspection of the exterior walls must
be made to ensure they remain in good condition.
For further information see the Rockcote Solid Walling Maintenance Guide.
5.12 Moisture
Rockcote Solid Walling systems must not be installed in contact with the ground. It must be installed in strict
accordance with the manual inclusive of exterior coating system, sealants, flashings, control joints and any
waterproofing systems to prevent the ingress of water, either by condensation or leakage through the wall or
adjacent construction components.
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5.14 Fire
Fully installed, the Rockcote Solid Walling-EPS System does not provide a fire rated wall. Rockcote Solid
Walling--EPS Walling is however manufactured from fire retardant polystyrene and will not support
combustion. RRR- EPS Walling must be separated from heat sources such as fireplaces, chimneys and
flues.
Rockcote has certification for BAL-29 for a Thermal Cavity system, please contact Rockcote for further
details.
5.15 Non-hazardous material
Fully installed, the RRR System is non-hazardous.
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6.0 INSTALLATION AND FIXING
6.01 Timber and steel wall framing
New framing
All timber and steel framing is required to be framed, braced, trimmed and finished in accordance with best
trade practice and to comply with the requirements of all relevant Australian Standards and Statutory
Authority requirements.
Maximum stud centres is 600mm apart.
Existing framing
Inspect existing framing and replace unsound timber.
Prime all exposed timber.
Maximum stud centres is 600mm apart.
Back blocking
Where EPS panels join off framing, back block the joint by fitting a piece of stud/noggin behind the joint
and fixing with glue, screws and washers. Refer to Section 7.01.
Solid backing
Solid timber backing is required for fixing taps, down pipes, lights, balustrading, pull-out or fold-down clothes
lines, etc.
Fitting
Before commencing to fit the EPS Battens & Wall Panels, check that the wall framing is straight and
within acceptable tolerances, all windows, doors and flashings are installed and solid back blocks are in
place. Fit starter strips to the base of the wall allowing at least 50mm overlap of the slab below floor level.
Refer to Drawing 7.01.02 - Batten Layout. EPS Walling can be installed either vertically or horizontally.
Battens and Panels are fitted into the starter strips, with panels glued and butted together at all joints,
apart from control/expansion joints. Screw off panels from the centre out to the edges at the required
centres along studs and around all edges (see Wind Loadings information in section 5.05). Overlap the
full thickness of the panel at internal corners. External panel joints are to be mitred. Fit the Rockcote Pre-
Meshed Trims to all external corners using ROCKCOTE Patch n Prep. Ensure that all the mesh is then
trowelled into the Patch n Prep. THIS ENSURES THE MESHED BEAD IS SECURED TO PROVIDE A
STRAIGHT AND TRUE CORNER. Ensure that panels and angle beads are straight and plumb, and allow
for the correct thickness of render and finish coating.
Bracing
EPS Walling is not a bracing board. Use EPS Walling ‘Over Bracing’ panels for fixing over plywood or
fibre cement wall braces.
Panels are easier to install if bracing is fitted to the inside of walls.
Gluing and sealing
Adhesives
Current testing indicates that Bostik ‘No More Nails’, HBFuller Toolbox & Maxbond, Bears ‘Stronghold’
and Fix-Tech Fixit Mate & Fix’N’Foam are suitable.
Sealants
Bostik ‘Seal n Flex’, Sika ‘Pro2 hp’, HB Fuller Superseal 101 and FixTech Fixseal MSP 15 are suitable.
Refer to adhesives and EPS panel manufacturers for current recommendation for use with EPS panels.
6.02 Cutting and drilling
A standard diamond masonry blade in a power saw is recommended to ensure an accurate and straight
cut. Set blade to thickness of panel. EPS Battens and Wall Panels can also be cut using a handsaw or
knife. Return unused off cuts to your local EPS recycling collection point or use them in the wall cavity for
extra insulation.
6.03 Beads
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ROCKCOTE Solid Walling System includes a range of suitable UV stabilised PVC trims. Starter trims to
suit 40mm, 60mm, 75mm and 100mm panels are available in external grade PVC. Reveals and external
corners should be finished with ROCKCOTE Solid Pre-Meshed Trim.
ENSURE REVEAL FLANGE IS FULLY GLUED TO EPS.
Window flashings are to be external grade PVC. Before applying sealant, clean and prime PVC. To
clean, apply acetone with a clean, dry cloth in one direction, and allow to flash off for 4 minutes before
priming. Alternatively Bostik N40 Primer may be used.
6.04 Expansion joints
Expansion joints are to be provided to allow for movement. Vertical control joints are required every 6
metres, and horizontal control joints are required every 3 metres or where timber or steel floor joists
occur. All control joints must utilise the ROCKCOTE Solid Walling System: Thermal Control Joint Trims.
Control joints must also be provided where ROCKCOTE Solid Walling System: Thermal meets other
cladding materials and where specified by a building design professional. Where control joints are to be
installed, the EPS panels must be independently fixed to studs/fixing points. Refer to Section 7.04.
6.05 Concrete and masonry walls
General
EPS System battens and panels are fixed to concrete and masonry walls by mechanical fixing.
Adhesive
ROCKCOTE Patch n Prep and FixTech ‘Fix’N’Foam foam adhesive have been used with success.
Mechanical fixings
Hilti IDP polypropylene anchors.
Fitting
Walls are required to be clean and free from dirt, oil, vegetation, crumbling or loose material.
Position the EPS battens & panels and drill (8mm bit) through into the masonry at each corner (offset in
by 100mm).
Use a minimum of 9 x IDP anchors per square metre.
When installing with render, apply fully to the back of the panel with a coarse notched trowel.
Panels are to be fitted into the starter strips and butted together.
All gaps are to be filled with EPS off cuts before fitting subsequent panels.
Overlap the full thickness of the panel at internal corners. External corners are to be mitred.
Mechanical fixings are to be installed at the rate of 9 fixings per m2.
6.06 Handling and storage
Care should be taken when handling EPS panels to avoid any damage to edges, corners and faces.
Panels must be stacked flat, off the ground and supported on a level platform. Goods stored in the
open are to be protected from prolonged exposure to direct sunlight and kept away from extreme heat
and organic solvents. Panels must be dry prior to fixing. Panels must always be carried on edge. Any
minor damage should be repaired with joint compounds or foamed polyurethane glue. Fixings and
other accessories must be stored so that they are kept clean, dry and undamaged.
6.07 Health and safety
Fully and properly installed, the ROCKCOTE SOLID-EPS System are non-hazardous. However, as with
all composite materials, general safety clothing and gloves are to be worn when handling or cutting EPS
battens & panels. It is recommended that a facemask and protective glasses be worn when cutting or
drilling the board. ROCKCOTE recommends that a qualified and authorised work place health and safety
officer (or equivalent) be consulted for specific advice.
ROCKCOTE is committed to maintaining a healthy and safe working environment, to ensure a project is
completed successfully and effectively, without compromising the health of any individual. To help
achieve this:
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• Provide a safe work place, including plant and equipment
• Actively encourage and insist that safe work methods are practised
• Provide supervision and appropriate training when required
• Ensure that all employees and other site visitors/workers understand and accept their responsibilities to
promote a safe workplace.
• Ensure that clients’ health and safety requirements and obligations are strictly adhered to.
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7.0 CONSTRUCTION DETAILS See relevant drawings in our website to illustrate each of the following details:
7.01 Panel fixing
See relevant Wind Loadings in Section 5.05 for fixing centres.
Timber Framing
NOTE: All timber screws must have at least 25mm of screw shaft screwed into the timber frame.
Fix 60mm EPS Wall Panels with 10-8 x 115mm Buildex Climacoat 3 CSK Ribbed Head Class 3 screws.
Fix 75mm EPS Wall Panels with 10-8 x 125mm Buildex Climacoat 3 CSK Ribbed Head Class 3 screws .
Washers for both are 10 x 40mm grey nylon.
Steel Framing
Fix 60mm RRR-EPS Wall Panels with Buildex 115mm Countersunk Steel Self Drilling 6-311-0621-1MP
screws.
Fix 75mm RRR-EPS Wall Panels with Buildex 125mm Countersunk Steel Self Drilling 6-311-0622-2MP
screws.
Washers for both are 10 x 40mm grey nylon.
Refer to 7.01.01 Panel Fixing and 7.01.02 Batten Spacing drawings.
7.02 Internal & External corners
It is important when forming internal and external corners that the drawings are followed correctly. In all
cases, the abutting corner panels should be bonded with suitable adhesive and sealed with polyurethane
sealants. Rockcote recommends mitring the corners as it creates a stronger joint with less risk of
cracking.
Refer to 7.02.01 External Corner and 7.02.02 Internal Corner drawings.
7.03 Control joints Control joints are required where specified by building design professional, and are designed to relieve structural movement between the wall cladding and building frame. Vertical control joints are required no further than every 6 metres. Double studs are required at all vertical control joints, ensuring polystyrene panels are independently fixed to studs or fixing points. Vertical joints are best aligned with windows, doors, openings, or internal corners. Horizontal control joints are required every 3 metres, or where timber or steel floor joists occur. Control joints must also occur where the ROCKCOTE Solid Walling System: Thermal meets other cladding materials. Rockcote recommends “V notching” the paintable flexible sealant in a control joint. Coatings can then be applied over the sealant. This allows for a clean straight control joint, any future minor movements within the joint results in the angle of “V notch” changing. If any cracking in the coating occurs it does so in a straight line. Refer to 7.03.01 Vertical Control Joint, 7.06.01 First Floor Detail and 7.03.02 EPS to Masonry Block drawings.
7.04 Termites
The Building Code of Australia, in conjunction with AS 3660, specifies the requirement for termite risk management. The edge of a slab-on-ground can be used as a visual perimeter barrier, provided that the slab edge is left exposed not less than 75mm above finished ground level, and provided that the face is not concealed by flashing, render, tiling, cladding or landscaping.
7.05 Slab on ground
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All foundations must comply with the relevant standards and local authority requirements. ROCKCOTE Solid Walling System: Thermal is suitable for construction on concrete slabs or suspended floors. Concrete slabs can either be rebated or non-rebated. The slab rebate needs to be a minimum 50mm below floor level and 100mm above paved level or 150mm above ground level (subject of course to compliance with statutory requirements). To ensure a flush finish, the width of the rebate needs to allow for the thickness of the ROCKCOTE Solid Walling System: Thermal, inclusive of the applied render and coating system. Minimum ground clearances must be maintained at all times during the life of the building.
Refer to 7.05.01 Rebated Slab Edge and 7.05.02 Slab Edge drawings.
7.06 Timber floor First floor / Horizontal Control Joint Details
It is important that a horizontal control joint is incorporated at the level of the flooring.
Refer to 7.06.01 First Floor Details
7.7 Wall to roof
It is important that a minimum 10mm gap is incorporated in-between the wall and roofing. This ensures
any wall or roof movement does not put pressure on the render system.
Refer to 7.07.01 Wall to Roof drawing.
7.8 Parapets
The correct detailing on Parapets is important to ensure that water ingress does not occur. Rockcote
recommends metal capping is placed over Parapets. The top of the parapet should be constructed to
shed water away from the visible wall face.
Refer to 7.08.01 Parapet drawings.
7.9 Soffit and eaves
The eaves or roof overhang play a significant role in the thermal performance of a building. Eaves or
overhangs are used to shade the walls in summer and to capture the sun’s heat in winter. It is important
that a gap is incorporated in-between the render system and the eaves. If a timber quad is not used then
this gap needs to be filled with a paintable polyurethane sealant.
Refer to 7.09.01 Soffit drawing.
7.10 Doors
Door framing must be fixed in position prior to installation of ROCKCOTE EPS wall panels. Cut
ROCKCOTE EPS wall panels neatly around but independently of door frames. There must be a minimum
3mm gap between the door frame and render system. This gap must be sealed with a suitable paintable
polyurethane sealant.
7.11 Windows
Windows and associated flashing should be installed prior to the installation of ROCKCOTE EPS wall
panels wherever possible. Rockcote has two different window sill profiles. One allows for the drainage of
any water ingress via weep holes. If a window sill is used it is important that these weep holes are not
rendered over.
Refer to Window Drawings 7.11.01 Window Sill Cavity Drained, 7.11.02 Window Sill Weep Hole, 7.11.03
Window Head and 7.11.04 Window Jamb
7.16 Decorative mouldings
To provide added design flexibility, decorative mouldings or features can be made by cutting the EPS
Wall Panels into bands or by laminating multiple layers and shaping to the desired profile. Once
installed, the full RRR coating system needs to be applied over the entire surface of the moulding.
Alternatively, a wide range of decorative mouldings are available from different manufacturers.
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7.17 Sunhoods
Sunhoods provide a simple, stylish, cost-effective shading option for window and door openings. The EPS
sunhoods are attached to engineered galvanized dipped steel brackets that are mechanically fixed to the
timber or steel frame.
Refer to 7.17.01 Sunhood Diagram
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8.0 FINISHING
8.01 Sleeve
Sleeve all copper, PVC products and electrical cabling that are required to penetrate the completed
ROCKCOTE SOLID - EPS System.
8.02 Penetrations
Weatherproof and/or waterproof voids or gaps created by service penetrations through the completed
ROCKCOTE SOLID- EPS System. Inject with expandable polyurethane foam and seal with a long lasting,
approved, paintable polyurethane sealant to make weather tight. Where practical, add a flange or decorative
feature over the hole or penetration.
8.03 Fixtures
Heavy items are not to be fitted directly to the ROCKCOTE SOLID- EPS System Wall Panels. Heavy
items require their own stand-alone supports or should be tied to the supporting wall frame (e.g. clothes
lines). Lightweight items subject to frequent handling (e.g. flood lights and sensors) also require a
mounting plate fixed to the frame to give long-term fixing support. The mounting plate must be installed
prior to fitting of the EPS Panels.
8.04 Sealants
Use an approved, paintable and flexible exterior grade weatherproof sealant as general purpose gap
filler. Apply sealant in accordance with the manufacturer’s recommendations. For a sealant to work
effectively, it must be applied so that the depth of sealant is twice the width of the opening.
Use a backing rod as required. Ensure surfaces are in good condition, clean and free from oil, dust, loose
materials and release agents. Apply masking tape to surfaces where contact with sealant is not required.
Tape should be removed before the sealant cures. Smooth the surface of the sealant to ensure excess
sealant is removed. Comply with sealant manufacturer’s directions for curing or drying times, before
painting.
8.05 Electrical Electrical wires must be separated from the EPS substrate to avoid plasticiser migration from the plastic coating around the electrical wires into the EPS, leaving them brittle and susceptible to cracking.