Tag Archives: hebel blocks

1.0 Introduction Power Block

CSR Panel Systems is a division of CSR Building Products Limited, one of Australia’s leading building products companies.

CSR Panel Systems manufactures Hebel Autoclaved Aerated Concrete (AAC). The AAC in Hebel products is manufactured from sand, lime and cement to which a gas-forming agent is added. The liberated gas expands the mixture, forming extremely small, finely dispersed air pockets, resulting in lightweight aerated concrete.

CSR Panel Systems has manufactured Hebel products that have won wide acceptance as innovative and environmentally preferable building materials. This is due to their lightweight nature, excellent thermal, fire and acoustic properties and design versatility. These inherent properties of Hebel products help achieve quick and cost efficient construction practices as well as providing for comfortable operating environments inside the buildings all year round.

Build a premium home with Hebel PowerBlock 

Hebel PowerBlocks are large AAC Blocks with a standard face dimension of 600mm x 200mm, laid in much the same way as bricks but using Hebel Adhesive to form a monolithic structure. Typically, external walls use a single skin of 250mm thick blocks while internal, non-loadbearing walls use 100mm thick blocks. Hebel’s tight manufacturing tolerances deliver beautifully flat, true surfaces that are easily rendered and painted.

Walls built with Hebel PowerBlock are strong and durable, providing the security of solid masonry coupled with exceptional thermal and acoustic insulation properties. With over three times the thermal resistance of double brick, Hebel PowerBlocks exceed the Building Code of Australia (BCA) for energy efficiency regulations for zones 1,2, 3 and 5 without the need for additional bulk insulation.

Hebel PowerBlocks are non combustible and can achieve an Fire Resistance Level (FRL) of up to 240/240/240.

For detached houses, this is well above the requirements for building right up to the boundary line and making Hebel an ideal choice for bushfire prone areas.

Compared to traditional double brick construction, Hebel PowerBlock walls can be laid much faster, saving building time and costs. Building with Hebel Blocks may create more internal floor area for the same building dimensions.

Hebel Lintels can be used over windows, doors and garage door openings. Hebel also supplies sill blocks for under windows to complement the overall look of your home.

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5.0 Acoustic Power Block

Table 5.1 provides acoustic performance levels for PowerBlock walls. For alternatives and composite wall construction, Table 3.2 are acoustic performance for PowerBlock systems.

Table 5.1:  Acoustic Performance

PowerBlock Thickness Rw Rw + Ctr
100 38 35
150 43 40
250 45 42

Values for PowerBlock only, no linings.

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9.0 Construction Notes Power Block

General Notes

1. These notes and details are to be read in conjunction with the project’s contract documentation.

2. All materials and workmanship shall be in accordance with this Installation Guide, the current edition of the Hebel Technical Manual and other Hebel documentation.

3. Refer to architectural drawings for all setting out dimensions.

4. Do not scale drawings, use written dimensions.

5. Should any omission, penetration, cutting of panels, discrepancy or fault exist, contact the designer immediately for a decision before proceeding with work.

6. All load-bearing walls, bearing on Hebel floor panels, shall be supported separately in accordance with the project engineer’s design.

7. Hebel accepts no responsibility for the design or selection of supporting walls, lintels, beams, columns or other structural members.

9. Corrosion protection of all structural steelworks shall be specified by the project engineer or architect.

10. The temporary restraint of walls is the responsibility of the builder or installer.

11. PowerBlocks on site should be protected against rain and water saturation. This can best be achieved by leaving the shrink-wrap cap on the top of pallets and covering the top of blockwork if rain threatens. PowerBlocks should not be laid in the rain.

IMPORTANT
12. Ensure engineering tie-down rods are present and located in accordance with the engineer’s documentation.

13. Ensure control joint locations are marked out in accordance with the engineering documentation.

Fig 9.1:  Wall Construction Diagram

Coatings

Table 9.1 details Hebel recommendations for Coating System options for Low Rise and Detached Residential construction to deliver a durable, monolithic appearance.

Hebel and Dulux Acratex have developed coating systems designed specifically for the Hebel AAC substrate and warrant these systems for 7 years. Performance requirements for alternate system options are provided. In such circumstances, the project specifier must satisfy themselves that systems are engineered and suitable for relevant project requirements.

General purpose, site or pre-bagged sand and cement renders must not be used on Hebel PowerBlock walls, owing to potential variability and unsuitability of formulation for Autoclaved Aerated Concrete (AAC).

Conventional exterior low build paint systems must not be used, as their ability to accommodate normal expansion and contraction in order to maintain a crack free protective layer is not assured.

Refer to “High Performance Coating Systems” brochure on the website, for more information.

Reinforcing Mesh Installation

Fully meshing all rendered Hebel surfaces using alkali-resistant glassfibre mesh is recommended to assist in maintaining render integrity and minimising consequential cracking. The minimum requirement is to mesh at corners of wall openings (doors and windows) to minimise corner cracking. The mesh should be embedded into the wet first pass of Hebel HighBuild.

Linings

Plasterboard can be direct fixed to internal Hebel PowerBlock walls. It is recommended that battens be used behind plasterboard linings on the inside surface of external walls. Fibre Cement sheet linings must be installed on battens.

Table 9.1 Coating systems for Hebel PowerBlock

Primer Acrylic Texture Body Coat Finish Coats
Hebel
Product
Finish
Style
Surface
Aign-
ment
Base
Render or
Levelling
Coat
Product
Descrip-
tion &
Perform-
ance
Guide
Dulux
Acra-Tex
Specifi-cation
Product
Descrip-tion &
Perform-ance
Guide
Dulux
AcraTex
Specifi-cation
Product
Descrip-tion &
Perfor-mance
Guide
Dulux
Acra-Tex
Specifi-cation
Comment
Power-
Block
Uniform
Sand
Texture
profile
≤3mm Hebel
High-Build
(Render)
Relevant to
coatings supplier
recomm-endations
Acra-Prime
501/1
OPTION 1:
1-2mm
Acrylic
Texture
Trowel
applied
Type:
AS4548.4
Polymer
content (dry):
9% min.
Tuscany
or
Coventry
Coarse
Elast-
omeric
Membrane
Type:
AS4548.1
Min DFT:
150 micron
Acra-
Shield
Matt
or
Elasto-meric
201
2nd coat
Elastomeric
Membrane
recommen-
ded
dependant
on project
complexity
eg.
unbroken
broadwall,
scaffolding
or cutting
in detail
and coastal
areas
OPTION 2:
Dependant on
specifier approval:
Sponge finishing 
of Hebel 
HighBuild
to a project
 approved
standard; plus
Elastomeric
Membrane
finishing system.
Elasto-meric
Membrane
Type:
AS4548.1
Min DFT:
250 micron
Elasto-meric
201
Hebel
recomme-
nds the
installation
of 1-2mm
Acrylic
Texture
Coat over
the render
base coat
providing
improved
consistency
of finish,
system
flexibility
and
durability.

PowerBlock Laying Procedure

1. First Course

a. Mix Hebel Mortar according to the directions on the bag.

b. Mix Hebel Adhesive according to the directions on the bag.

c. Lay a DPC (damp proof course) slip joint membrane at the base of all external and internal walls to allow for differential movement between the blocks and the slab/ footing. Cut the DPC around tie rods as required. The DPC must be installed on the slab/footing prior to the application of Hebel Mortar.

d. Lay Hebel Mortar to get first course level and plumb. Accurately position a block and tap into place with a rubber mallet. Ensure that the block is level in all places.

e. All loose particles and dust must be brushed from the base and vertical end surfaces of all first course blocks before bedding in Hebel Mortar and applying Hebel Adhesive.

f. Apply Hebel Adhesive to the perpend of the base blocks using a Hebel notched trowel that matches the block thickness. Ensure full width coverage with 2-3mm final joint thickness.

g. Position the next block vertically adjacent the first block. Place the block down into position and gently tap the block end horizontally with a rubber mallet to fully close the vertical joint.

h. Tap the block vertically into the base mortar and level with the first block.

i. Repeat until the first course is complete.

j. Bore holes in blocks for tie-down rods using a 40-50mm auger bit and place over rods where required. Rod must be central in hole.

2. Second and Subsequent Courses

a. All loose particles and dust must be brushed from the top of the first course before applying Hebel Adhesive.

b. Apply Hebel Adhesive to the horizontal surface using a Hebel notched trowel that matches the block thickness.

c. Overlap the block joints a minimum of 100mm over joints in the previous course. Normal practice is to overlap by thickness of the intersecting wall.

d. Install wall ties where required, locating centrally accross block thickness and bed into the Hebel  Adhesive.

e. Position the first block in the second course and gently tap accurately into place with a rubber mallet. Joints must be 2-3mm thick.

f. Apply Hebel Adhesive to the perpend of the first block. Position the next block vertically adjacent the first block. Place the block down into position and tap the end with the rubber mallet to fully close the perpend joint. Joints must be 2-3mm thick.

g. Tap the top of the block until level with the previous blocks laid.

h. Repeat for subsequent blocks.

i. Excess adhesive should be cleaned off the block face at the end of each course within 1-2 hours.

j. Large holes can be patched using Hebel Patch in accordance with the directions on the bag.

k. Bore holes in blocks for tie-down rods using a 40-50mm auger bit, and place over rods where required. Rod must be central in hole.

l. Where required construct a bond beam in the top course of loadbearing walls. Minimum dimension is 100mm wide x 200mm high. Use minimum 50mm thick blocks each side to form up bond beam. Reinforcement to be minimum 2x N12 deformed bars. Refer to Floor Panel Note 2 for grout specification.

m. Where required construct a ring beam in the top course of the non-loadbearing walls. Cut/rout 60mm x 60mm recess and place 1x N12 deformed bar centrally. Refer to Floor Panel Note 2 for grout specification.

3. Finishing

a. Ensure that all perpends are completely filled with Hebel Adhesive.

b. Ensure holes and chips are completely filled with Hebel Patch. Sand back level.

c. Clean off any remaining Hebel Adhesive runs.

d. The blocks can be sanded when dry to ensure a good surface is presented for surface coatings.

4. Base Rendering and Sealants

a. Mix up Hebel HighBuild render in accordance with the instructions on the bag.

b. Apply alkali- resistant glass fibremesh at corners of wall openings (doors and windows) to minimize corner cracking. The mesh should be embedded into the wet first pass of Hebel HighBuild.

c. Hebel HighBuild should be applied with a hark and trowel with minimal thickness of 6mm. General purpose, site or prebagged sand and cement renders must not be used on Hebel Autoclaved Aerated Concrete.

d. Render must be stopped at control joints to allow the joint to open/close and function correctly.

e. All control joints and gaps between blockwork and framing around windows must be caulked with an appropriate flexible sealant.

f. Install backing rods approx 10mm from surface.

g. Apply primer to the surfaces.

h. Installed sealants to manufacturer’s specifications.

5. Coatings for External Walls

a. Coatings must comprise a high build acrylic texture coat and finish elastomeric paint membrane.

b. Conventional exterior low build paint must not be used.

c. Allow Hebel HighBuild to fully cure (approx 24 hours depending on weather conditions).

d. Apply primer to the Hebel HighBuild.

e. Apply texture body coat such as Dulux AcraTex. Ensure texture coat stops at control joints.

f. Apply finishing sealants in control joints.

g. Apply first finishing paint elastomeric paint membrane.

h. Apply second coat of elastomeric paint membrane as required.

i. Refer to manfuacturer’s guidline for coating on AAC PowerBlock work and Hebel HighBuild.

6. Internal Linings

a. Plasterboard can be direct fixed to internal Hebel PowerBlock walls.

b. It is recommended that battens be used behind plasterboard linings on the inside surface of external Hebel PowerBlock walls.

c. Fibre cement sheet linings can not be direct fixed to Hebel PowerBlocks. Installed fibre cement sheets linings on battens.

d. Hebel HighBuild render may be directly applied to internal block walls as per pervious instructions.

Floor Panel Notes

1. The ring anchor reinforcement shall be a minimum of N12 grade in accordance with AS1302, unless noted otherwise by the project engineer.

2. Hebel Mortar should be used as grout for the ring anchor system. A nominal composition of 1 Cement: 4 Sand (5mm maximum coarse aggregate) can also be used. Minimum compression strength of f’cg= 15MPa at 28 days.

3. Additives to reduce the grout shrinkage shall only be used in accordance with the manufacturer’s instructions.

4. The installer shall support (chair) reinforcement to enable grout to fully surround the reinforcement. Reinforcement shall not be in contact with the panel when grout is placed.

5. Grout shall be rodded to ensure complete filling of notch and groove.

6. The installer shall provide notch and groove at panel joints as per Hebel standard detail 5.3.5 on page 7.60 in the Hebel Technical Manual..

7. Ensure notch is cleared of all loose material and reinforcement cleaned of all foreign material.

8. Lightly pre-wet notch prior to pouring the grout.

9. Panels shall only be cut on-site as indicated on the engineer’s drawings, otherwise contact your distributor or sales representative.

10. Propping of panels may be required to accommodate minor misalignments until 3 days after ring anchor grout is poured.

11. All propping shall be removed from Hebel Floor Panels before any walls are erected over.

12. Traffic on floor panels is to be avoided for a period of 3 days after the ring anchor grout is poured.

13. All panel dimensions are the responsibility of Hebel’s client and are subject to approval by the client before commencing manufacture of panels.

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14.0 Construction Details (Typical) Power Block

Base of Wall

Fig 14.1 Hebel PowerBlock work on Stiffened Raft Slab Edge Foundation (elevation)

 

Fig 14.2 Hebel PowerBlock work showing infill block to slab rebate (elevation)

Fig 14.3 Internal Load Bearing Hebel PowerBlock work on stiffened raft slab foundation (elevation)

 

Fig 14.4 Concrete PowerBlock Sub-Floor Detail (elevation)

 

Fig 14.5 Roof Top to Plate Fixing to Hebel Wall – Strap (elevation) – for vaulted/cathedral roofs

 

Fig 14.6 Roof Top to Plate Fixing to Hebel Wall – Strap (elevation) – for typical trussed roof

 

Fig 14.7  Strap Fixing to Hebel Walls (isometric – typical trussed roof)

 

Fig 14.8  Double Brick Sub-Floor Detail (elevation)

 

Fig 14.9 Ring Beam Internal Non-Loadbearing Wall (elevation)

Top of Wall

Fig 14.10 Internal Hebel Load Bearing Wall and Timber Floor Frame Junction (elevation)

 

Fig 14.11 Truss Spanning Over Non-Load Bearing Hebel Walls (elevation)

 

Fig 14.12 Timber Truss/Joist Fixed to Hebel Walls (elevation)

 

Fig 14.13  Tiled Roof Eve and Hebel Wall Junction (elevation)

 

Fig 14.14  Vaulted Ceiling & Roof Top Plate Fixing To Hebel Wall (elevation)

Wall Junctions

Fig 14.15 External Wall and Internal Partition Wall Junction (plan)

 

Fig 14.16  External Corner with Control Joint (plan)

Control Joints

Fig 14.17  Control Joint detail (elevation)

 

Fig 14.18 Typical Bond Beam Control Joint – elevation

 

Fig 14.19 Typical Control Joint – plan

 

Fig 14.20 Typical Ring Beam Control Joint – elevation

 

Fig 14.21 Hebel PowerBlock work Typical Movement Joint Detail (elevation)

 

Fig 14.22 Hebel PowerBlock work Typical Movement Joint Detail (plan)

 

Fig 14.23 Built-in Column Detail (plan)

 

Fig 14.24 Built-in Column Detail (elevation)

Floor

Fig 14.25 Non-Load Bearing Hebel PowerBlock Wall and Hebel Floor Panel Detail (elevation)

 

Fig 14.26 Loadbearing Hebel PowerBlock Wall and Floor Panel Junction Detail (elevation)

 

Fig 14.27  Loadbearing Hebel PowerBlock Wall and Timber Floor Frame Junction Detail (elevation)

 

Fig 14.28 Timber Floor Support Detail (elevation)

 

Fig 14.29  Hebel Flooring Panels using Ring Anchor Construction on Load Bearing Interior Wall (elevation)

 

Fig 14.30 Ceiling Support Detail A (elevation)

 

Fig 14.31  Ceiling Support Detail B (isometric)

Balcony and Deck

Fig 14.32  Balcony Detail (elevation)

 

Fig 14.33  Balcony Detail (elevation)

 

Fig 14.34  Deck Connection Detail (side elevation)

 

Fig 14.35 Deck Connection Detail (front elevation)

Stairs

Fig 14.36  Stairwell (isometric)

 

Fig 14.37  Stair Tread Set-Out (isometric)

 

Fig 14.38 200mm wide x 50mm thick Hebel PowerBlocks adhered to walls on their ends to provide support for treads (isometric)

Openings

Fig 14.39 Steel Door Frame (Internal or External) to Hebel® Wall Fixing (plan)

 

Fig 14.40  Steel Door Frame (Internal or External) to Hebel Wall Fixing (plan)

 

Fig 14.41  Timber Door Frame (External) to Hebel Wall Fixing (plan)

 

Fig 14.42  Timber Door Frame (Internal) to Hebel Wall Fixing (plan)

 

Fig 14.43  Aluminium Window Frame – Window Sill Detail (elevation)

 

Fig 14.44 Aluminium Window Frame – Window Jamb Detail (elevation)

 

Fig 14.45  Aluminium Window Frame – Window Head Detail (elevation)

 

Fig 14.46 Lintel Installation
(a) Elevation

(b) Section

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Appendix A – Carpet Installation Power Block

Panel Surface Preparation

Sweep the floor surface to remove debris and loose particles. Expose all surface blemishes such as  chips, cracks, gaps, ridges or the like. Fill all unacceptable locations with an appropriate and compatible patching compound such as Hebel Patch or levelling compound as required. Ensure panels are then dry.

Carpet Smooth Edge Installation

Installation of Carpet Smooth Edge (Gripper) is to be in accordance with AS/NZS 2455.1:1995.

Installation of carpet gripper prior to laying carpet requires the use of specifically selected nails or course threaded screws. Standard fixings supplied with the carpet gripper are not suitable for fixing to Hebel PowerFloor panels. Carpet gripper strips are available without factory supplied nails. For carpet gripper installation near the panel edge, only glue is recommended. If relying on glue only, the carpet can not be stretched until the glue is set after approximately 24 hours.

Table A.1 – Carpet Smooth Edge Fixings

Fixing Type Description Application Method Installation Notes
Twist Nails 51mm dome
head twist nail
Coil Nail Gun (Refer to Fig A.1) The head of the twist nail should finish flush with the surface of the gripper strip
Screws Type 17 point - course thread No. 8g x 50mm – Countersinking screw Makita 6834 Auto Feed Screwdriver (Refer to Fig A.2) The head of the twist nail should finish flush with the surface of the carpet gripper strip
Screws Type 17 point-Trimhead deck Screw.
4.2 x 50mm
4.2 x 65mm
Quickdrive auto feed The head of the screw should be flush with the smooth edge

Underlay Installation

Minimum medium duty underlay is to be used. No other special requirements.

Carpet Installation

As per carpet manufacturer’s guidelines.

No other special requirements.

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1.0  Introduction Hebel PowerFloor

CSR Hebel

CSR Hebel is 100% owned by CSR Building Products Limited, one of Australia’s leading building products companies. CSR Hebel manufactures and markets a range of lightweight Autoclaved Aerated Concrete (AAC) blocks, reinforced panels, cladding and lintels for use in the housing and commercial construction industry. CSR Hebel also sells complimentary mortars, tools and accessories.

In 1989, CSR became involved with Hebel and established the Australian operation. Since then, Hebel has won wide acceptance as an innovative and environmentally friendly building material due to its speed of construction, excellent thermal/fire/acoustic properties and its design versatility.

Design Overview

As environmental consciousness and social responsibility increases, Hebel is striving to exceed these ideals and set new standards in building materials and residential living.

Designed for inner comfort

With Hebel wall and floor solutions, clients can enjoy a comfortable interior in their home, and be comfortable with their choice for the environment. Materials uses a small fraction of the energy and natural resources used in manufacturing conventional masonry, producing almost no waste or by-products. The highly efficient insulating properties of Hebel also save power in heating or cooling the home.

Designed for inner peace

Hebel wall and floor solutions help you create a tranquil inner space. We have worked closely with acoustic exper ts and testing authorities to engineer inherently superior acoustics from our wall and floor systems. They create a sound barrier to external noise and from other rooms within the home.

Designed for peace of mind

Although it’s remarkably lightweight, Hebel is solid and durable. Hebel panels are reinforced with steel for extra strength. Hebel is also extremely fire-resistant and is not a food source for termites.

Designed to save

As they’re lightweight and modular, Hebel materials are quick to assemble, saving building time and costs. They also minimise the need for supporting materials, saving budget resources and energy compared to a suspended concrete slab.

Use Hebel for Better Framed Construction

  • Hebel is a lightweight material, which reduces the structural load on the home, and its requirements for supporting building materials.
  • Their low weight makes Hebel panels ideal for use in difficult applications such as sloping sites.
  • A floor of Hebel panels is steelreinforced, solid and secure.
  • Hebel PowerFloor has better thermal efficiency than suspended timber or concrete floors, resulting in reduced heating and cooling costs. Hebel’s cellular structure allows you to use framed construction and still have excellent insulation and thermal mass.
  • Hebel PowerFloor has a fire rating of at least three hours from above and up to two hours from below with an appropriate Gyprock ceiling system.
  • Hebel panels and floors provide better acoustic insulation than many other materials.

CSR Hebel PowerFloor

Hebel PowerFloor is an innovative flooring panel suited to residential, commercial and industrial applications. The lightweight nature of Hebel PowerFloor makes it ideal for sloping sites, for suspended floors, where access is difficult, for tiled surfaces, or where reduced footing sizes are required.

Various floor coverings and conventional ceiling systems can be combined with Hebel PowerFloor to produce a range of systems.

The primary component of these systems is the Hebel PowerFloor panel. Hebel PowerFloor can be quickly installed over timber or steel floor framing using construction adhesive and screw fixing.

Hebel PowerFloor, together with a suitably designed and built supporting frame structure, exhibits a more rigid response than other lightweight framed flooring systems. This behaviour is attributed to composite action between the Hebel PowerFloor panel and the joist, as well as the load sharing to adjacent joists. Hence, Hebel PowerFloor will provide a stiffer, lightweight floor, with a ‘reinforced concrete’ feel.

The inherent thermal qualities of AAC in Hebel PowerFloor contribute to cost savings associated with annual heating and cooling of a residence.

The acoustic performance also directly assists in reducing the high noise levels of urban environments.

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5.0  Architectural Specification Hebel PowerFloor

This specification should be adopted as a guide only, and shall be superseded by the contract specifications of the project.
* Insert or select appropriate specifications.

Scope

The contractor shall furnish all material and equipment required to satisfactorily complete the installation and jointing of Hebel PowerFloor where indicated in the contract specification.

Materials

All AAC material shall be a Hebel PowerFloor panel as manufactured by CSR Hebel.

All accompanying fixings shall be those supplied by CSR Hebel or approved by the project engineer.

All lining materials shall be Gyprock plasterboard as manufactured and supplied by CSR Gyprock (or products of equivalent or better performance). All plasterboard shall be manufactured to meet the dimensional requirements of AS/NZS2588Gypsum Plasterboard’.

Steel frame components shall be those manufactured by Rondo Building Services Pty Ltd (or products of equivalent or better performance).

Construction adhesive shall be Fuller Max Bond as manufactured and supplied by Fuller (or products of equivalent or better performance).

All sealants shall be a polyurethane type with required fire and acoustic ratings, (or products of equivalent or better performance).

All infill materials shall be products manufactured and supplied by CSR Bradford (or products of equivalent or better performance).

PowerFloor System

The contractor shall supply and install a Hebel PowerFloor system *PF-………(…), in accordance with CSR Hebel Detached Houses & Low Rise MultiResidential Floor Design Guide, NºHBLA185, and CSR Gyprock Fibre Cement Fire & Acoustic Design Guide (‘The Red Book‘), NºGYP500, and shall satisfy the following performance criteria.

The Hebel PowerFloor system shall have a Fire Resistance Level of *FRL…/…/… for a fire source ‘from above’ in accordance with the requirements of AS1530.4. Design of the joists shall allow for temperature effects.

Installation shall be carried out to the level specified for a field acoustic performance of *Dntw………… using cavity infill of *Bradford …………… (or products of equivalent or better performance).

Levels of Finish – Floor Covering

Prior to installation of the floor covering, the contractor shall ensure the installed panels are within the tolerances of the project specifications. The contractor shall ensure that all control joints are installed as per project specifications, panel joints are completely filled with Hebel Adhesive, minor chipping damage of the panels shall be patched with Hebel Mortar, and all sealants are installed as per manufacturer’s specifications.

Floor coverings shall be installed as per manufacturer’s specifications, unless specified otherwise in the contract documentation.

Ceiling System

The contractor shall supply and install the Gyprock Ceiling System *N°CSR………in accordance with CSR Gyprock Fibre Cement Fire & Acoustic Design Guide (‘The Red Book‘), NºGYP500. The ceiling framing shall be lined with *……… layers of……… mm Gyprock……… plasterboard.

Levels of Finish – Ceiling Systems

All ceiling framing systems, plasterboard lining, jointing and finishing shall be carried out to *Level ……… Level of Finish, in accordance with CSR Gyprock Plasterboard Residential Installation Guide, NºGYP547, AS/NZS2589.1 ‘Gypsum Linings in Residential and Light Commercial Construction – Application and Finishing’.

Plasterboard

The Hebel PowerFloor system ceiling framing shall be lined with *………… layer/s of …………mm Gyprock ……………… plasterboard.

Plasterboard fixing

All layers shall be fixed to the framing (ie., timber or steel floor joists and/or steel furring channels) as specified for the relevant system in the CSR Gyprock Ceiling Systems Installation Guide, NºGYP570, other relevant CSR Gyprock technical literature, and Rondo Building Services Pty Ltd literature or steel frame manufacturer’s literature.

Jointing & Finishing

Jointing and finishing of the outer layer of plasterboard shall be in accordance with the CSR Gyprock Plasterboard Residential Installation Guide, NºGYP547.

Caulking

Where caulking is indicated in fire rated systems *…………………… fire rated polyurethane sealant or fire rated backing rod with *……………… acoustic rated polyurethane sealant shall be used, and installed in accordance with the manufacturer’s recommendations.

Where caulking is indicated in wet areas, a *…………………… polyurethane sealant must be used when caulking *non-fire rated/fire rated wet areas, as indicated, and installed in accordance with the manufacturer’s recommendations.

Important

Any variation or substitution of materials or assembly requirements, or compromise in assembly may result in failure under critical conditions.

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1.0 Introduction Party Wall

CSR Hebel

CSR Hebel is 100% owned by CSR Building Products Limited, one of Australia’s leading building products companies. CSR Hebel manufactures and markets a range of lightweight Autoclaved Aerated Concrete (AAC) products. The current product range includes blocks, reinforced panels, cladding panels and lintels for use in the residential and commercial construction industry. CSR Hebel also sells complimentary mortars, tools and accessories.

In 1989, CSR became involved with Hebel and established the Australian operation. Since then CSR Hebel has manufactured products that have won wide acceptance as innovative and environmentally friendly building materials. This is due to their lightweight yet solid nature, excellent thermal, fire and acoustic properties and design versatility. The inherent properties of CSR Hebel products help achieve quick and cost efficient construction practices as well as providing for comfortable operating environments inside the buildings all year round.

Design Overview

As environmental consciousness and social responsibility increases, CSR Hebel is striving to exceed these ideals and set new standards in building materials and residential living.

Designed for inner comfort

With CSR Hebel wall and floor solutions, clients can enjoy a comfortable interior in their home, and be comfortable with the choice for the environment. Manufacture of CSR Hebel materials uses a fraction of the energy and natural resources used in manufacturing conventional masonry, producing almost no waste or by-products. And CSR Hebel AAC’s highly efficient insulation saves power in heating or cooling the home.

Designed for inner peace

CSR Hebel wall and floor solutions help create a tranquil inner space. We have worked closely with acoustic experts and testing authorities to engineer inherently superior acoustics from our wall and floor systems. They create a sound barrier to external noise and from other rooms within the home.

Designed for peace of mind

Although it’s remarkably lightweight, CSR Hebel AAC is solid and durable. CSR Hebel panels are reinforced with steel for extra strength. CSR Hebel is also extremely fire-resistant and is not a food source for termites.

Designed to save

As they’re lightweight, CSR Hebel materials are quick to assemble, saving building time and costs. They also minimise the need for supporting materials, saving budget resources and energy.

Use CSR Hebel for Better Sound Insulation

With advances in technology (particularly the home theatre system) and consumer’s demand for home listening pleasure the need for wall and floor systems offering excellent sound insulation has developed.

Recognising the unique properties of AAC, CSR Hebel was one of the first building products manufacturers to respond to this growing need by developing a range of acoustic wall systems. Since then the peace and amenity of thousands of multiunit households and commercial developments have benefited from Hebel PartyWall.

As of the 1st May 2004 the Australian Building Codes Board (ABCB) announced that the minimum Building Code of Australia (BCA) sound insulation requirements have been increased. CSR Hebel’s acoustic performance will help you reach the new standard, while also benefiting from the unique lightweight yet solid feel of CSR Hebel products.

Hebel Low Rise Multi-Residential Party Walls

Hebel Low Rise Multi-Residential Party Walls have been developed to provide an effective fire barrier and to satisfy the ever-growing demand for noise abatement in multi-residential framed dwellings. The systems provide cost effective, slender wall sections, with acoustic and fire performance conforming to and exceeding the BCA requirements. Hebel PartyWall systems can achieve Rw + Ctr ratings of 50dB or better.

These PartyWall systems consist of specific combinations of Hebel PowerPanel, CSR Bradford insulation and CSR Gyprock plasterboard or CSR Cemintel fibre cement sheet. These are used to create a symmetrical wall system, which have minimal components and are relatively compact. The resulting walls exhibit high acoustic insulation and fire resistance performance, which have been proven through registered test facilities.

The primary component of the wall is the Hebel PowerPanel, which is a 75mm thick, steel reinforced panel, manufactured from CSR Hebel AAC. The AAC in CSR Hebel products is manufactured from sand, lime and cement, to which a gas-forming agent is added. The liberated gas expands the mixture, forming extremely small, finely dispersed air pockets, resulting in lightweight aerated concrete.

As with other CSR Hebel products, Hebel PowerPanel exhibits excellent thermal and fire resistance properties. Hebel PowerPanel is lightweight and easily handled, typically by only two people.

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7.0 Sound Transmission & Insulation PartyWall

7.1 Overview

The Building Code of Australia (BCA) presents the Performance Requirements for sound insulation ratings. The sound insulation ratings set minimum values to consider two types of sound: airborne sound and impact generated sound. The Performance Requirements for airborne sound insulation and impact sound insulation ratings are dependent upon the form of construction (i.e., walls or floors), Class of Building, and the type of areas being separated. The airborne sound performance requirement is a value that could be the weighted sound reduction index (Rw) or weighted reduction index with spectrum adaptation term (Rw+Ctr). The impact sound performance requirement is a value called the weighted normalised impact sound pressure level with spectrum adaptation term (Ln,w+ Cl). The BCA does provide Performance Requirements for the airborne sound and impact generated sound insulation ratings for a party wall. Refer to Tables 6.1 and 6.2 for sound insulation resistance level of the Hebel PartyWall systems.

7.2 Impact Sound Performance

Impact sound is caused by vibrations, which are transferred directly through the wall and re-radiated as sound in the adjacent room. These sound vibrations can be generated by actions such as closing of a cupboard door.

The transfer of impact sound can be minimised by ensuring no mechanical connection exists between the two sides of the wall. For impact rated walls the new BCA requires walls to be of ‘discontinuous construction’. This refers to a wall maintaining a minimum 20mm cavity between two separate leaves except at the periphery.

Note: For gap widths ≤ 20mm, CSR Hebel has obtained expert opinion that discontinuous construction performance will not be compromised.

7.3 Acoustic Performance Design Recommendations

1) CSR Hebel recommends engaging a specialist acoustic consultant on a project-by-project basis to provide design advice, confirmation of anticipated field performance, detailing and installation inspections.

2) When selecting the appropriate Hebel PartyWall, the designer or specifier must be aware that the laboratory Rw values are almost always higher than the field measured values. Therefore, allowances should be made for the lower expected field values during the selection of the system.

3) Separate advice from a specialist acoustic consultant should be sought to determine the effect on acoustic performance due to any changes to the Hebel PartyWall systems, and any required modification of the installation details pertaining to the systems.

4) Increasing of cavity widths, using higher density or thicker insulation or plasterboard, will generally maintain or increase the acoustic performance of the Hebel™ PartyWall.

5) The acoustic performance values of the Hebel PartyWall systems shown in Tables 6.1 and 6.2 are a guide only as to consistently achievable field performance. They do not constitute a field performance guarantee as factors such as the presence of flanking paths, quality of installation of the system, on-site detailing of junctions, room shapes and size, etc can significantly affect field performance. Maximising the field performance depends on the following factors:

The systems are installed in accordance with the manufacturer’s standard installation details.

  • Good quality installation practices including the sealing of all junctions and joints and maintaining specified clearances.
  • The systems are installed with all junctions acoustically sealed so that negligible sound transmission occurs at these points.
  • Flanking paths are eliminated and the structures into which the systems are installed are capable of allowing the nominated rating to be achieved.
  • Site testing conditions.
  • To minimise the transfer of sound through the Hebel PartyWall system into the adjacent unit, it is suggested that a control joint be provided to break the mechanical path for the transmission of impact sound and other vibration.

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10.0 Design & Detailing Considerations Party Wall

10.1 Control Joints

Control joints must be provided at a maximum of 6m spacing. Recommended control joint widths should be 10mm minimum between Hebel PowerPanel and another building component. Control joints must also be provided to coincide with any control joint in the main structure. Larger joint width maybe required to accommodate building movements, and these values shall be nominated by the designer. The top hat and back to back track must be discontinuous at a structural control joint.

10.2 Wet Area Wall Construction

Wet area wall construction requires a system that enables services to be installed in a cavity. All plumbing should be acoustically treated as required by the BCA. All wet area walls shall be lined and waterproofed in accordance with Australian standards and to BCA requirements. Gyprock Aquachek or Cemintel Fibre Cement Wallboard are suitable lining materials for wet area applications.

10.3 Non-Hebel Components Used in Party Wall

Components, which are not manufactured by CSR Hebel, such as CSR Gyprock plasterboard, timber and steel stud wall frames, CSR Bradford insulation and others must be designed, installed and handled in accordance with their manufacturer’s guidelines and recommendations.

CSR Building Products Limited, guarantees only the products that are manufactured by CSR Building Products Limited, not the components, products or services supplied by others.

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