AUGUST 2012EXTERNAL FACADE SYSTEM (INCLUDING CEMINSEAL BARESTONE™)
CSR CEMINTEL™
EXPRESSWALL FC:126
Cemintel ExpressWall™ offers an expressed joint facade system for an extensive range of commercial and industrial applications. Panels available are ExpressPanel™, which can be painted on-site, and BareStone™, a pre-finished panel with a raw concrete appearance.
2 CEMINTEL EXPRESSWALL™
CoNTENTSDescription 2
ApplicAtions 2
expressWAll™ ADvAntAges 3
components 4–6
Design consiDerAtions 7–14
top HAt FrAming 15–16
pAnel prepArAtion 17–19
pAnel instAllAtion 20–23
curveD FAcADes 24
construction DetAils 25–32
Fire rAteD WAll systems 33–36
ArcHitecturAl speciFicAtion 37
mAteriAl properties 38
HAnDling & storAge 39
sAFety 39
pAnel cutting 39
HeAltH & sAFety 40
guArAntee 40
DESCRIPTIoNFocused on taking a fresh look at the building market, CSR Cemintel™ has a range of products that make buildings look great and work better.
Cemintel’s range of creative products have ‘a look’, finishes that inspire people, which they aspire to have on and in their buildings. Whether it be the unique colours and textures provided by the Designer Series or the traditional weatherboard look of Scarborough, CSR Cemintel has the products to help you create a stunning facade.
Drawing upon the best knowledge in the industry, CSR Cemintel constructive solutions improve the speed in which buildings are built and the way they work. Ranging from the industry first CeminSeal, which provides 95% stronger joint and compound adhesion to Permafloor, a new lightweight structural flooring product that can be gun nailed for ease of installation, Cemintel people consistently challenge themselves to take a fresh look at solving key industry issues.
APPLICATIoNSThe Cemintel ExpressWall™ system has been designed to be used for external cladding buildings such as:
• SupermarketsandShoppingcentres.• OfficeBuildings.• MostCommercialBuildings.• ResidentialHomesandApartmentBuildings.• OranyotherapplicationnotexcludedbytheDesign
Considerations section of this brochure.
It however remains the responsibility of the building designer to verify the Cemintel ExpressWall™ system is suitable for the particular requirements of any given project.
The Cemintel ExpressWall™ System has excellent resistance to water penetration and high wind loads, and is suitable for exposed applications.
The ExpressWall™ System can also be used as an exterior ceiling. Contact CSR Gyprock & Fibre Cement for details.
CEMINTEL EXPRESSWALL™ 3
DESIGN FEATURES• Expressedjointappearance.
• Flat,smoothfinishwithcountersunkscrews.
• Readilyacceptsmanyformsofdecorativefinish.
• ExposedheadfastenersforBareStone™ and pre‑painted panels.
• Pre-finishedBareStone™ with natural cementitious appearance.
• Testedweatherresistance.
• Designedforextremewindpressures.
• Lightweight,lowmaintenancefacadesystem.
• Suitableforcurvedapplications.
CONSTRUCTION FEATURES• Highlydurablegaskets.
• Dimensionallyaccuratepanels.
• Highprefabricationopportunity.
• Panelseasilyreplaced.
• HighperformanceExpressWall™TopHat1.15:
–SuitableforCyclonicAreas.
– Wide fixing surface for increased installation tolerance.
EXPRESSWALL™ ADvANTAgES
ExpressWall Backing Strip
Structural support
ExpressWall Horizontal Gasket
ExpressWall Vertical Gasket
Adhesive
ExpressWall Top Hat
Intermediate Top Hat
Sarking
ExpressPanel™ or BareStone™ Panel
Countersunk HeadFastener
Exposed HeadFastener
4 CEMINTEL EXPRESSWALL™
EXPRESSPANEL™
ExpressPanel™ is a compressed fibre cement sheet which is purpose manufactured for use in building facades. ExpressPanel™ is factory sealed on both faces and all edges. The white face is ready to accept a wide range of finishes. ExpressPanel™ is 9mm thick, has a mass of 17kg/m2, and is available in the following panel sizes;
CeminSeal BareStone™ Sizes. (All panels 9mm thickness)
Width (mm)
Length(mm)
1800 2100 2400 2700 3000
900 3 3 3
1200 3 3 3 3 3
note: please contact csr gyprock & Fibre cement for nonstandard expresspanel™ sizes.
ExpressPanel™ Face Identification
CEMINSEAL BARESTONE™ PANELCeminSealBareStone™ Panel is a compressed fibre cement sheet which is purpose manufactured for use in building facades.CeminSealBareStone™ Panel has water blocking agents embedded in the sheet and does not require a finish tobeapplied.CeminSealBareStone™ Panel is 9mm thick, hasanaturalfibrecementcolour(grey),amassof17kg/m2, and is available in the following panel sizes.
CeminSeal BareStone™ Sizes. (All panels 9mm thickness)
Width (mm)
Length(mm)
2400 3000
1200 3 3
note: please contact csr cemintel for non-standard ceminseal Barestone™ panel sizes.
CeminSeal BareStone™ Back Face Identification
The back face of the panel is clearly marked
BARESTONE™ TOUCH-UP KITForcoatingtheedgesofBareStone™ panels that have been cut on‑site.
OrderN° Quantity
100166 200ml
CoMPoNENTS
White outside face suitable for coating
Outside face
Clear finish to inside face – Not suitable for coating
CEMINTEL EXPRESSWALL™ 5
20 2050
15
EXPRESSWALL™ TOP HATExpressWall™TopHatisapurposedesignedrolledsteelsection for supporting the vertical edges of the panels. The unique profile also acts to accommodate movement of the sheets at the vertical joints. It is designed to be used in conjunction with the ExpressWall™ Vertical Gasket.
ExpressWall™TopHatismanufacturedfromgalvanised(Z275)steel,andisthesubjectofpatentapplicationNº2003900205.
ExpressWall™TopHat1.15BMTisrequiredforcyclonicareasand when exposed head screws are to be used, including all BareStone™ installations.
BMT OrderNº Length(m) Masskg/m
1.15 39124 6.0 3.25
0.75 84746 6.0 1.97
INTERMEDIATE TOP HATIntermediateTopHat isusedtosupportthepanelsatlocationsotherthanverticaljoints.IntermediateTopHatisa Rondo rolled steel section which is manufactured from galvanised(Z275)steelof1.15mmBMT.
BMT OrderNº Length(m) Masskg/m
1.15 21086 3.6 1.38
1.15 21083 72 1.38
TOP HAT H515TopHatH515isfixedtostructuralsteelframingtosupportthe ExpressWall™andIntermediateTopHats.TopHatH515is a Rondo rolled steel section which is manufactured from galvanised(Z275)steelof1.15mmBMT.
BMT OrderNº Length(m) Masskg/m
1.15 12884 3.6 0.91
1.15 100896 7.2 0.91
EXPRESSWALL™ VERTICAL GASKETExpressWall™ vertical gasket is made fromEPDMclosedcellfoam which has high UV resist ance. The gasket has adhesive on one side (with a release paper), and is adhered to the ExpressWall™TopHattopreventmoisture entry at vertical joints.
OrderNº Description
221063.2mmx48mmx25mroll
(Tesa61102)
EXPRESSWALL™ HORIZONTAL GASKETExpressWall™ horizontal gasket is madefromclosedcellPVCNitrilefoam which has a high resist ance to abrasion and maintains i ts properties at high temperatures. The gasket has adhesive on one side (with a release paper), and is adhered to the ExpressWall™BackingStriptopreventmoistureentryathorizontal joints.
OrderNº Description
221053.0mmx18mmx9mroll
(Tesa50601)
EXPRESSWALL™ BACKING STRIPExpressWall™BackingStripisarolledsteelsection designed to support the gasket and/or sealantbehind thehorizontalexpressed joints. ExpressWall™BackingStrip is manufactured from high tensile Colorbond steel, and is black in colour.
OrderNº Length
21089 1194mm
21088 2394mm
21087 2994mm
20 2050
35
2222 295529
35
59
1711.15 BMT
5252 246 6 24
35
53
163
0.75 BMT
60mm
6 CEMINTEL EXPRESSWALL™
EXPRESSWALL™ SCREWSExpressWall™ Screws are specially designed for the ExpressWal l™ System. They a re the on ly screws recommended by CSR for f ixing ExpressPanel™ and BareStone™ panels to the steel top hats.
Countersunk Head Screw:
TheCountersunkHeadallowsconcealedfixing,andthebuttress thread is designed to provide maximum holding power in light gauge steel. It has a Class 3 finish and is gray in colour. For ExpressPanel™ only.
OrderN° Description
114070CountersunkHeadClass3
Finish1000/pack
Exposed Head Screw: (Suitable for ExpressWall™TopHat1.15.ONLY).
TheExposedHeadScrewhasabuttressthreadwhichisdesigned to provide maximum holding power in light gauge steel. It is available in Class 3 finish and Stainless Steel (grade410).ForExpressPanel™andBareStone™ panels
OrderN° Description
114081WaferHeadClass3Finish
1000/pack
28626WaferHeadStainlessSteel
1000/pack
EXPRESSWALL WEATHER SEALThe ExpressWall™ Weather Seal is a grey, UV stabilised nylon washer. I t is used wi th ExpressWal l™ ExposedHeadScrewstoprovidean interference fit, delivering high weather resistance and acting to lock the screw into position.
OrderN° Description
36484 Weather Seal
HEX HEAD SCREWFor f ixing top hats to steel framing in non‑cyclonic areas. Hexheadselfdrillingscrew12-14x20.(Suitabilitytobeconfirmed by project engineer).
OrderN° Qty
84882 1000
COUNTERSINKING TOOLThis is a tungsten carbide tipped tool specifically designed for drilling and countersinking the required 6mm diameter screw ho les inExpressPanel™. It is suit able for use with screw guns and drills, and has an adjustable depth setting. This is the only tool recommended by CSR for this purpose. Use only for countersunk head screws
OrderN° Description
22116 Countersinking Tool
BACKING STRIP ADHESIVEAnadhesiveisusedforfixingExpressWall™BackingStriptopanels.TherecommendedproductisSikaflex®-11FC.Thisproduct is not recommended for filling expressed joints.
OrderN° Description
39378 Sikaflex®11FC,310mltube
SARKINGBradfordfoilproductsareusedtoprovidethermalinsulationandmoistureprotection.Thermofoil733isadoublereflectivefoil for high thermal rating.
Product OrderN° Qty
EnviroSeal™ Wall Wrap
13462 1350mmx20mroll
Thermofoil733 81333 1350mmx60mroll
30mm
Class 3 finish
30mm
Stainless Steel
30mm
Class 3 finish
To Suit Hole
CEMINTEL EXPRESSWALL™ 7
40mm
20°
20mm
40mm
CAVITY BAFFLEPVC prof i le used at base of wall to exclude vermin and moisture.
OrderN° Length
38651 3.0m
SEALANTSealant is used to seal ExpressWall™ joints for high wind loads, control joints, junctions, etc. Can be painted over with most paints. It is also required at expressed joints where prepainted ExpressPanel™ has been used.
OrderN° Description
11378 Sikaflex®PRO,310mltube(colourGrey)
39488 Sikaflex®PRO,310mltube(colourBlack)
Othersealantsmaybeusedfordecorativepurposes,whenapproved by the manufacturer.
EPOXYEpoxy is used to conceal the countersunk fastener heads, to prevent moisture penetration, and to provide a flat surface for decorative coating. Epoxy products must be installed to the manufacturer’s recommendations.
Recommended products are:• MegapoxyP1.• HiltiCA125*.• HiltiCA273*(shouldbeusedwhenambient
temperatureislessthan15°Cattimeofinstallation)
OrderN° Description
25464 MegapoxyP1,1litrekit
BOND-BREAKER TAPEBond-breakertapeisusedbehindsealantathorizontaljoints,forexamplewhenthedesignwindpressureexceeds4.0kPa.
OrderN° Description
13172Tesa7492
(3.2mmx48mmx25m).
BACKING ROD*
Backingrodisusedtoenablecorrectfillingofjointswithsealant. It is recommended that backing rod be of open cell type to enable sealant to cure from behind. The diameter of backing rod must be appropriate for the width of the gap being filled.
FLASHINGS & CAPPINGS*Flashings are to be designed and installed in accordance with SAA-HB391997andgoodbuildingpractice.
*NotsuppliedbyCSR.
DESIgN CoNSIDERATIoNSThis guide represents good practice, though it is not intended as an exhaustive statement of all relevant information. It remains the responsibility of the building designer to verify that the Cemintel ExpressWall™ system is suitable for the particular requirements of any given project.
DESIGN RESPONSIBILITYPanels, top hats and structural framing are required to resist windloadsthatarespecifictothebuildingsite.Additional‘local pressure factors’ apply to the panels and top hats in accordancewiththewindcode,AS1170.2.Itisrecommendedthat the building designer assigns responsibility for the facade design to the project engineer. This is to ensure consistency of wind load determination and proper integration of the facade with the structure.
Oncewindloadshavebeendetermined,tophatspansandspacings, and sheet fixing details, may be selected from the appropriate tables in this manual.
It is also the responsibility of the building designer to select theappropriatecorrosivitycategory.RefertoTable1, onpage10.
8 CEMINTEL EXPRESSWALL™
HIGH WIND LOADSInareaswherethedesignwindpressuresexceed4.0kPa,additional sealing is required to minimise water ingress. Refer toFIG31and32foradditionaldetails.
In cyclonic areas ExpressWall™TopHat1.15mmmustbe used.
Windloadsinthisguidereferto‘UltimateLimitStateDesignWind Pressures’.
SARKINGThe ExpressWall™ facade is designed as a rain screen, and if exposed to weather, appropriately designed sarking must be used between the top hats and the framing. If the wall is not exposed directly to the weather and will not get wet during storms, sarking is only required for insulation and condensation control. Sarking must be designed and installedinaccordancewithAS/NZS4200Part1:Materials,and Part 2 : Installation.
Condensation is a complex problem, and can occur under avarietyofconditions,notjustcoldconditions.LiteratureonthissubjectisavailablefromCSIRO/BRANZ/ASHRAEand must be consulted when building in areas where condensation is likely to occur.
In these cases, the appropriate use of a sarking as a vapour barrier or as thermal insulation, or both, can be effective in controlling condensation.
THERMAL PERFORMANCE
expressWAll™
•1layerorBareStone™ or ExpressPanel™ fixed to Cemintel ExpressWall™ top hat framing system.
•InsulationandSarkingaspersystemtable.
•TimberorSteelStuds(90mmmin.)at600mmmaximumcentres.
•1layerx10mmGYPROCKplasterboardCDfixedtotheinsideofframing.
Insulation in Cavity Sarking Winter
Total Wall R-Value
Summer Total Wall R-Value
(a)NilBRADFORDENVIROSEALWallWrapunder top hats
1.2 1.0
(b)NilBRADFORDTHERMOFOIL733undertop hats
1.7 1.4
(c)BRADFORDGold battsR1.5
BRADFORDENVIROSEALWallWrapunder top hats
2.1 1.9
note: *Bradford thermofoil 733 is sarking with reflective finish both sides. using an alternative product with anti-glare finish will reDuce the stated r-value performance.
INSULATIONIt is recommended that insulation materials be installed to enhance thermal insulation properties and occupant comfort. Insulation also improves the acoustic performance of the wall against outside noise.
The level of insulation provided in a wall is determined by its R‑value. The higher the R‑value the greater the insulation provided. Cemintel ExpressWall™ Systems incorporating BradfordR1.5GoldInsulationcanprovideathermalratingofR2.1,whichisgreaterthanmanymasonrysystems.
PANEL FINISHES
• ExpressPanel™
ExpressPanel™ is factory sealed on both faces and all edges. Sealing in this manner increases the durability and stability of the panels. The exterior surface of the ExpressPanel™ must becoatedwithanappropriatefinish.Notethatthebackface of panels cannot be painted, and is not suitable as an exterior finish.
Where panels are cut on‑site, sealing of the cut edges shall bewithDuluxAcra-Prime501/1.Theminimumapplicationrateshallbe1litreper10m2(140grams/m2)whichresultsinadryfilmthicknessof70microns.Alternatively,coatwithundilutedBondcretebeforeapplyingthefinishcoating.
CEMINTEL EXPRESSWALL™ 9
The exterior face of ExpressPanel™ can be finished with any of a wide variety of coatings, provided they are compatible with the ExpressPanel™ seal coat, ExpressWall™ screws and with the epoxy used to cover the countersunk heads. Highbuild,exteriorgradeacrylicpaintoraggregatefinishesprovide the best results. Exposed vertical gaskets should not be painted and Sikaflex Pro sealant may be painted if required
ExpressPanel™ may be painted off‑site when exposed head screws are to be used. Refer to appropriate painting contractors for details and colours. For pre‑painted panels, it is a requirement that all expressed joints are filled with sealant. Refer to Panel Installation.
Aminimumdryfilmthicknessof250micronsisrecommendedtoensureadequatecoverfortheconcealedfasteners.Highgloss and low build finishes will require additional surface preparation to minimise fastener show‑through. In all cases the coating manufacturer’s application instructions must be followed. The inside face of the ExpressPanel™ is finished clear and is not suitable for painting.
Beforeapplyingfinishesincoastalareas(refertodefinition),all panels must be thoroughly washed with fresh water to remove any salt residue. Refer to coating manufacturer for additional requirements.
• BareStone™
TheproductionofCeminSealBareStone™ panels incorporates waterblocking agents that are embedded in the sheets. That is, the panels are delivered ready to install and do not require afinishapplied.Notethatthebackfaceofthepanelisclearlymarked. It may exhibit production marks and should not be confused with the front.
Where panels are cut on‑site, treatment of the cut edges is required.ApplyBareStone™Touch-upKitliberallybybrush.
CONTROL JOINTSControl joints in the ExpressWall™ system are required to correspond to control joints in the supporting structure and anywhere that significant structural movement is expected.
Ahorizontalcontrol joint is requiredbeneathslabstoaccommodate any expected deflection. The magnitude of the deflection must be verified by the building designer. RefertoFIG35and36.
Vertical control joints to allow for differential movement are required at the supports of fascia trusses and at the junction of structural elements of different stiffness, such as between concrete columns and stud frames.
RefertoFIG40,4142and50.
DURABILITYCemintel ExpressPanel™&CeminSealBareStone™ panels have many properties which make them very durable products, including:
•Immunetopermanentwaterdamageinbothshortandlong‑term exposure.
•Willnotrot,burnorcorrode,andisunaffectedbytermites, air, steam, salt and sunlight.
•Notadverselyaffectedoveratemperaturerangeof0ºCto95ºC.
MAINTENANCEThe durability of the ExpressWall™ system can be enhanced by periodic inspection and maintenance. Inspections should include examination of the coatings, flashings and seals. Paint finishes must be maintained in accordance with the manufacturer’s recommendations.
ThenaturallookofBareStone™ panels is expected to change little over time, and the original appearance can generally be maintainedbywashingwithwater.Notethatifdetergentsareused they should be removed with clean water.
BareStone™ panels may also be coated with a water based exterior‑grade acrylic paint or a clear sealer, and then maintained in accordance with the manufacturer’s specifications. The coating product must have suitable durability and be recommended by the manufacturer for use with masonry substrates.
Anycrackedordamagedfinishorsealswhichwouldallowwater ingress, must be repaired immediately by recoating or resealing the effected area, or by removing the panel and replacinggaskets.Anydamagedflashings,sheetsorgasketsmust be replaced as for new work.
For details on system requirements in different environments refertoTable1.Itisthedesigner’sresponsibilitytodeterminethe Corrosivity Category, based on site conditions.
The durability of the system can be increased by the additional treatment of steelwork, and by painting all exposed sealants to the sealant manufacturer’s recommendations. In corrosivity category C4, barriers to reduce the ingress of salt laden air are required.
10 CEMINTEL EXPRESSWALL™
Table 1: Requirements for Corrosive Environments
Corrosivity Category(AS4312)
ExposedHeadScrews
CountersunkScrews Joints Additional
Maintenance
C1:VeryLowC2:Low
Class 3 or Stainless Steel Class 3 Sealed or Expressed –
C3:Medium Class 3 or Stainless Steel Class 3 Sealed or Expressed Wash‑down
C4:High Stainless Steel Class 3 Sealed Wash‑down
C5:VeryHigh NotSuitable NotSuitable – –
TableNotes:•SealedJoints:Allhorizontalandverticaljointsmustbecompletelyfilledwithsealant.RefertoFIG31and32.•Wash-down:•Allwallsmustbesufficientlyexposedfromabovesothatraincanperformnaturalwash-downofthewall. OR•Wallswhichareprotectedbysoffitsabovemustbewasheddowntwiceperyear,toremovesaltanddebrisbuild-up,particularlyatjoints.
CORROSIVITY CATEGORIESCorrosivitycategoriesareasdescribed inAS4312 -AtmosphericcorrosivityzonesinAustralia.Thecodehasmethods for determining categories as well as maps and tables of major population centres.
C1: Very Low
Generally inside buildings, semi‑sheltered locations away from marine or industrial influence, and some alpine regions.
C2: Low
Dry, rural areas, away from the coast or sources of pollution. MostareasofAustraliaatleast50kilometresfromthecoast,which can extend to within one kilometre from quiet, sheltered seas.Most inlandtowns,suchasCanberra,Ballarat,ToowoombaandAliceSprings,andsuburbsofcitiesonshelteredbays(Brisbane,Melbourne,Hobart)thataremorethanonekilometrefromthesea.Adelaidesuburbsmorethan6kilometresfromthecoastinthesouthernsuburbs,throughto 3 kilometres from the coast in the northern suburbs.
C3: Medium
Coastal areas with low salinity, extended by factors such as wind, topography and vegetation. Sheltered areas such asPortPhilipBay50metresfromtheshorelinetoaboutonekilometreinland.Aroundlessshelteredbayssuchas
Adelaidetoabout3to6kilometresinland.Alongoceanfrontareas with breaking surf and significant salt spray extending fromaboutonekilometreinlandtobetween10and50kilometres inland, depending on the strength of prevailing winds and topography. Includes much of the metropolitan areasofWollongong,Sydney,NewcastleandtheGoldCoast,mostoftheYorkePeninsulaSouthAustralia,andfromVictorHarbourtotheVictorianborder,extendingbetween30and70kilometresinland.Urbanandindustrialareaswithlow pollution levels, and for several kilometres around large industries such as steelworks and smelters.
C4: High
Aroundshelteredbaysupto50metresinlandfromtheshoreline.Areaswithroughseasandsurf,extendingfromseveral hundred metres inland to about one kilometre inland and depends on winds, wave action and topography. Up to 1.5kilometresdownwindoflargeindustrialplants.
C5: Very High
Offshoreandonthebeachfrontinregionsofroughseasandsurf beaches, and inland for several hundred metres, e.g. aroundNewcastleextendingoverhalfakilometrefromthecoast.AggressiveindustrialareaswheretheenvironmentmaybeacidicwithapHoflessthan5.
CEMINTEL EXPRESSWALL™ 11
STRUCTURAL SUPPORTExpressWall™TopHatsandIntermediateTopHatsmustbeinstalled vertically, and supported by a primary structural system.
ExpressWall™ top hats can be fixed to horizontal structural steel framing which is commonly used for large walls and buildings.
FIG 1: Fixing to Structural Steel Framing
ExpressWall™ framing can also be fixed over masonry or concretewalls.Alltophatconnectionsmustbedesignedbythe project engineer.
FIG 2: Fixing to Existing Masonry Wall
Concrete footing
ExpressWall Top Hat
Intermediate Top Hat
Structural steel frame
ExpressWall Top Hat
Intermediate Top Hat
Masonry wall
12 CEMINTEL EXPRESSWALL™
Alternatively, ExpressWall™ framing can be f ixed to appropriately designed steel or timber framing. This is commonly used for small walls and buildings. The frame must be designed to support the top hats at the top and bottom of the wall, and at cross members within the span of the wall. The connection of the cross member to the frame requires engineering design.
AS/NZS1170.0TableC1suggeststhatsupportframingbedesignedforamaximumdeflectionofspan/250.
Table 2: Vertical Spacing of H515 Top Hats – Horizontal Top Hats Fixed to Three or More Studs
WindLoadkPa
VerticalSpacingofH515TopHats(mm)
StudSpacing(mm)–Studs0.75BMT StudSpacing(mm)–Studs1.15BMT
300 450 600 300 450 600
1.0 3040 2020 1520 4640 3090 2320
1.5 2020 1350 1010 3090 2060 1540
2.0 1520 1010 760 2320 1545 1160
2.5 1210 810 600 1850 1230 920
3.0 1010 670 500 1540 1030 770
3.5 860 570 430 1320 880 660
4.0 760 500 380 1160 770 580
4.5 670 450 330 1030 680 510
5.0 600 400 300 920 610 460
5.5 550 360 270 840 560 420
notes: top Hat to stud connection is 2 x nº12g screws through top hat legs. Wind loads are ultimate limit state. top Hat serviceability deflection < span / 240. stud frame design by others.
FIG 3: Fixing to Steel or Timber Framing
Concrete footing
Structural steel frame
Top track
Intermediate Top Hat
ExpressWall Top Hat
Bottom track
Top Hat (H515)
Top Hat (H515)
Top Hat (H515)
Top Hat (H515)
CEMINTEL EXPRESSWALL™ 13
PANEL LAYOUTPanel layout for the ExpressWall™ system involves the coordination of the following:
•Aestheticdesign.•Tophatspacingtoallowforexpressedjointwidths.
Refer to FIG: 4.•BareStone™ and ExpressPanel™ size and joint width.
(Horizontaljointsare10to20mmwideandverticaljointsare6to20mmwide).
•Typeofstructuralsupport.•Openings–sizeandlocation.•Buildingsize.•Buildingcontroljointlocation.
FIG 4: Typical Top Hat Set-out – 1200mm Width Vertical Panels with 10mm Joints shown
605mm 605mm
1200mm Sheet
Furring Channel Spacing
Furring Channel Spacing
FIG 5: Horizontal Sheeting Aligned Grid Pattern
FIG 6: Horizontal Sheeting Half-bond Pattern
Panel layout can be in a grid pattern where vertical and horizontal joints are continuous. Panels may be positioned vertically,horizontallyorrotatedupto45ºintheplaneof the wall.
In these layouts, construction joints may be positioned behind any vertical or horizontal sheet joint. For details on control joints, refer to page 29.
Panel layout can also be in a vertical or horizontal half‑ bond pattern where some joints are discontinuous.
FIG 7: Vertical Sheeting Aligned Grid Pattern
FIG 8: Vertical Sheeting Half-bond Pattern
14 CEMINTEL EXPRESSWALL™
GASKETSGaskets are used at horizontal and vertical joints to maintain weather resistance.
Theverticalgasket ismadefromEPDMrubberwhichhas good weathering and UV resistance. It has very low compression set and water permeability.
ExpressWall™TopHat1.15hasbeendesignedtoelasticallydeform when pressure is applied during panel f ixing. ExpressWall™TopHat0.75hasarecessedareatoacceptthe gasket. These designs ensure that only the required pressure is applied to the vertical gasket.
FIG 9: Vertical Gasket Compression
FIG 11: Joint Detail
Thehorizontalgasket isaclosedcellPVCNitrilefoamwhich has a high resistance to abrasion and maintains its properties at high temperatures. It is highly conformable and has excellent resistance to water penetration.
FIG 10: Horizontal Gasket Compression
ExpressWall Top Hat 1.15
Vertical Gasket
ExpressWall Countersunk Screw
Panel
Horizontal Gasket
Backing Strip
Panel
Panel
Backing Strip and Gasket deform to create effective seal
ExpressWall Backing Strip
ExpressWall Horizontal Gasket
ExpressWall Vertical Gasket
Sikaflex-11FC
ExpressWall Top Hat
ExpressWall Fastener
ExpressPanel or Barestone panel
CEMINTEL EXPRESSWALL™ 15
ToP HAT FRAMINgThe design capacities of the ExpressWall™ system are in limit stateformatandintendedforusewithAS/NZS1170.2.Thesystem is suitable for cyclonic wind zones, Region C and D, andhasbeentestedinaccordancewithAS4040.31992.
To obtain equivalent permissible load capacity divide the ‘UltimateWindCapacities’inTable3orTable4by1.5.
The top hat capacities in Table 3 and Table 4 have been calculated inaccordancewithAS4600:ColdFormedSteelStructuresandareapplicablefor0.75and1.15BMTExpressWall™TopHatsandfor1.15BMTIntermediateTopHats.ThedeflectionofthetophatsasdetailedinTable3andTable4isnomorethanspan/250whensubjectedtoserviceabilitywindloadsof68%ofultimatewindloads.
TABLE 3: Ultimate Wind Capacity (Refer to FIG 12)
Single Span Installation
TopHatSpan(mm)
NominalTopHatSpacing*
450mm 600mm
Ultimate WindCapacity
(kPa)
Ultimate WindCapacity
(kPa
9009501000
6.006.005.41
3.503.503.50
110012001300
4.143.182.42
3.142.411.83
140015001600
1.871.481.19
1.421.120.91
170018001900
0.980.810.69
0.740.620.52
200021002200
0.580.500.44
0.440.380.33
*Nominaltophatspacingsof450mmand600mmaresuitableforactualspacingsofupto460mmand610mmrespectively.Forpanelsfixedtoaminimumofthreetophats,withtophatspacingof400mmnominal(410mmmax.),andwithsingleordoubletophatspanofupto900mm,theultimatewindcapacityis7.0kPa.
FIG 12: Single Span Installation
Top Hat Spacing
Top Hat Span (Table 3)
Cantilever
Cantilever
Maximum Cantilever = 0.2 x Adjacent Top Hat Span
16 CEMINTEL EXPRESSWALL™
TABLE 4: Ultimate Wind Capacity (Refer to FIG 13)
Double Span Installation
TopHatSpan(mm)
NominalTopHatSpacing*
450mm 600mm
Ultimate WindCapacity
(kPa)
Ultimate WindCapacity
(kPa
9009501000
6.006.006.00
3.503.503.50
110012001300
5.844.914.18
3.503.503.17
140015001600
3.603.142.76
2.732.382.09
170018001900
2.442.131.77
1.851.621.34
200021002200
1.491.261.08
1.130.960.82
*Nominaltophatspacingsof450mmand600mmaresuitableforactualspacingsofupto460mmand610mmrespectively.Forpanelsfixedtoaminimumofthreetophats,withtophatspacingof400mmnominal(410mmmax.),andwithsingleordoubletophatspanofupto900mm,theultimatewindcapacityis7.0kPa.
TOP HAT FIXING (Refer to FIG 14)
note: it is the responsibility of the project engineer to specify the connection of the top hats to the support structure.
Eachfastenerisrequiredtohaveaminimum14mmdiameterhead,suchasa12ghexheadscrew,forsatisfactorytophatperformance.Incyclonicareas,minimum14ghexheadscrewsand1.15BMTtophatsarerequired.
FIG 14: Top Hat Fixing
FIG 13: Double Span Installation
If adjacent spans differ by more than 25% then single span values must be adopted.
MaximumCantilever=0.2xAdjacentTopHatSpan
Cantilever
Cantilever
Top Hat Spacing
Top Hat Span (Table 4)
Top Hat Span (Table 4)
Fixing
ExpressWallIntermediate Top HatFixing
ExpressWall Top Hat
CEMINTEL EXPRESSWALL™ 17
PANEL PREPARATIoNExpressPanel™andBareStonepanelpreparationmaybeperformedoff-sitepriortoinstallation.Allcutpanelsmusthave edges painted as noted in Panel Finishes.
Prior to lifting into place:1.Drillholesthroughthepanelsforscrews,and
countersink if required.2.Affixhorizontalgaskettobackingstrips.3.Affixbackingstripsbehindthetopedgeofpanelsand
allow adhesive to set.
PANEL FIXING SET-OUTPanelsmustbefixedinaccordancewithTable5.Appropriatepanel fixing layout should be selected for the project Design WindPressure,TopHatSpacingandPanelFixingType.(RefertoFIG16and17).
For curved facades, please refer to page 24.
Table 5: Panel Fixing Requirements
Design Wind Pressure (Ultimate)
(kPa)
Max.TopHatSpacing(mm) Max.FixingSpacing(mm)
Panel Fixed to TwoTopHats SeeFIG16.
Panel Fixed to ThreeormoreTopHats
SeeFIG17.
at Panel Edge ‘X’ (mm)
atIntermediateTopHat ‘Y’
(mm)
1.0
1.5
600
450
600
600
600
600
600
600
2.0
2.5
450
450
600
600
400
400
400
350
3.0
3.0
450
450
600
450
400
400
300
400
3.5
3.5
400
400
600
450
300
350
250
350
4.0
4.5
400
400
450
450
300
300
300
250
5.0
5.5
300
300
450
450
300
250
200
200
6.0
6.5
7.0
300
300
300
450
400
400
250
250
250
200
200
200
FIG 16: Panel Fixed to Two Top Hats Only
FIG 15: Panel Fixing Set-out
*Minimumdistanceoffastenertoedgeof35mm.
FIG 17: Panel Fixed to Three or More Top Hats
45mm*
45mm*
45mm*
Fixing Spacing at Panel Edge (refer to Table 5)
Fixing Spacing at Intermediate Top Hat(refer to Table 5)
‘X’
‘Y’
* Minimum distance of fastener to edge of 35mm.
Top Hat spacing Top Hat spacingTop Hat spacing
18 CEMINTEL EXPRESSWALL™
PRE-DRILLING HOLESHolesforscrewsmustbepre-drilled.Usetherecommendedcounter sinking tool for countersunk head screws, and a 6mmmasonrybitforexposedheadscrews.Holesmustbe6.2mmto6.3mmindiameter.Donotusehammeractionwhen drilling. Clean dust out of holes.
FIG 18: Fastener Pre-drilling for Countersunk Head Screws
note: use only the recommended tool as supplied by csr. the use of other tools for this purpose may reduce fixing capacity or reduce the weather resistance of the system.
HINT:Onewayofdrillingholesistodrillthetopsheetofapackwiththecountersinkingdrillsettoapproximately12mmdepth. This will give a starter hole on the sheet below, saving on set out time.
FIG 19: 6mm Masonry Drill for Exposed Head Screws
BACKING STRIP FIXINGBackingstripisinstalledbehindallhorizontalpaneljoints.Backingstripistobe6mmshorteroverallthanthewidthofthe panel (cut to length if necessary) and adhered to the back ofthepanel(alongthetopedge)withSikaflex-11FC.
FIG 20: Backing Strip Positioning
Backingstrip isadheredtothebackofpanelswithacontinuousbeadofSikaflex-11FC.Thebeadmustbeasuitable size so that when pressed flat, adhesive fully covers the interface between the backing strip and the panel. The adhesive must be allowed to cure before the panel is installed.
Note: Use only the recommended tool as supplied by CSR. The use of other tools for this purpose may reduce fixing capacity or reduce the weather resistance of the system.
ExpressWall Backing Strip
ExpressWall Horizontal Gasket
mm3mm3
Panel
5mm
Panel
Backing Strip
For 10mm Horizontal Joint
For 20mm Horizontal Joint
Note: Use only the recommended tool as supplied by CSR. The use of other tools for this purpose may reduce fixing capacity or reduce the weather resistance of the system.
6mm
CEMINTEL EXPRESSWALL™ 19
AfilletofSikaflex-11FCisthenplacedalongthetopedgeofthe panel. This ensures that the joint drains and that salt and dirt will not build up at the joint.
FIG 21: Horizontal joint
HORIZONTAL GASKET FIXINGApplytheExpressWall™HorizontalGaskettotheuppersection of the backing strip, keeping the gasket in line with thetopofthebackingstrip.(Alternatively,thiscanbedoneprior to fixing the backing strip to the panel).
FIG 22: Horizontal Gasket Installation
SEALING ENDS OF BACKING STRIPTo seal the groove in the backing strip at the ends, apply a small section of gasket to the rear of the backing strip. This will be forced into the recess and seal the end of the strip. AlternativelyuseSikaflex-11FCtofillthegroove.
FIG 23: Sealing Ends of Backing Strip
Panel
Sikaflex-11FCadhesive
Backing Strip
ExpressWall Horizontal Gasket
10mm wide x 18mm long strip of Horizontal Gasket
Panel
Sikaflex-11FC
Backing Strip
Panel
ExpressWall Horizontal Gasket
20 CEMINTEL EXPRESSWALL™
PANEL INSTALLATIoN Panels must be in a dry condition when fixed. If panels become wet after installation, allow to dry before covering screw heads.
Panels must only be fixed using Cemintel ExpressWall™ Screws.BareStone™ panels must only be fixed using ExposedHeadScrews.
Installing panels is a three step process:
1.InstallVerticalGasketstoExpressWall™TopHats.2. Screw fix Panel to top hats.3. Cover fastener heads (when using countersunk head
screws).
CSR recommends the use of torque control screw guns.
If it is necessary to remove and replace a panel, avoid reusing screw holes in the top hats by adjusting fixing locations in the panel.
INSTALLING VERTICAL GASKETInst all vertical gasket to central section of the ExpressWall™ TopHatforthefullextentofpanels.Becarefulnottostretchthe gasket when installing. When joining gasket, cut ends cleanly and push together before adhering.
FIG 24: Vertical Gasket Installation
When top hat is discontinuous, butt ends together tightly and continue gasket over the joint. If a gap is present, install a steel strip to support the gasket.
FIG 25: Gasket Support at Discontinuous Joint (0.75 Top Hat shown)
FIXING PANELS USING COUNTERSUNK HEAD FASTENERSDrive the countersunk head screw into the top hat using an electric screw gun. CSR recommends the use of a screw gun with torque control to prevent overdriving of screws.
FIG 26: Fixing with Countersunk Screws to Top Hat 0.75
ExpressWall Top Hat 1.15
ExpressWall Vertical Gasket applied centrally on top hat
ExpressWall Top Hat 0.75
ExpressWall Vertical Gasket applied centrally in recess
ExpressWall Top Hat 0.75
ExpressWall Countersunk Screw
ExpressPanel
30mm
Class 3 finish
ExpressWall Top Hat 0.75
ExpressWall Countersunk Screw
ExpressPanel
30mm
Class 3 finish
Steelstrip
10mm max.
CEMINTEL EXPRESSWALL™ 21
PANEL FIXING USING EXPOSED HEAD FASTENERSInstall the ExpressWall™ Weather Seal into the pre‑drilled hole in the panel. Drive the exposed head screw through the weather seal and into the top hat using an electric screw gun. CSR recommends the use of a screw gun with torque control to prevent overdriving of screws.
Exposedheadscrewscanonlybeusedwith1.15BMT top hats as screws can strip in the lighter gauge.
FIG 27: Fixing with Exposed Head Screws
JOINTSPanelsaregenerallyinstalledwithanominal10mmwidth,horizontal and vertical expressed joints between adjacent panels.Jointsupto20mmnominalwidthcanbeformed,provided additional care is taken during installation to ensure that panel edges cover the joint gaskets by a minimum of 10mm.
FIG 28: Vertical Joint Detail
FIG 29: 10mm Horizontal Joint Detail
FIG 30: 20mm Horizontal Joint Detail
*Minimumdistanceoffastenertoedgeof35mm.
Exposed Head Screw
ExpressWall™ Top Hat 1.15
Weather Seal compressed in
hole and compressed around screw thread
Sealant where required
ExposedHead Screw
ExpressWall Weather Seal
Panel
Pre-drilled hole
Panel
ExpressWall Vertical Gasket 6-20mm
ExpressWall Top Hat
ExpressWall CSK Screw
Horizontal Gasket
Backing Strip
Panel
Panel
45mm*
45mm*
10mm
Horizontal Gasket
Backing Strip
Panel
Panel
45mm
45mm
20mm
* Minimum distance of fastener to edge of 35mm.
22 CEMINTEL EXPRESSWALL™
For ExpressWall™ systems subjected to design wind pressure inexcessof4.0kPa,orincorrosiveenvironmentsasdetailedinTable1onPage10,allhorizontalandverticaljointsmustbe filled with recommended joint sealant. Sealant is also required where prepainted panels are used. Sealant must be installed in accordance with the manufacturer’s instructions.
FIG 31: Sealed Vertical Joint Detail
*Minimumdistanceoffastenertoedgeof35mm.
Atthebeginningandendofaverticaljoint,suchaswithsheets installed in a half‑bond pattern, continue the vertical gasketpast thehorizontal jointby100mmminimum. Refer to FIG 33.
FIG 33: Vertical Gasket and Fixing Detail for Half-bond Panel Layout
Joint filled with sealant
ExpressWall Top Hat
ExpressWall Screw
ExpressWall Vertical Gasket6-20mm
Panel
Horizontal Gasket
Backing Strip
Panel
Panel
45mm*
45mm*
10-20mm
Joint filled with sealant over Bond-breaker Tape
* Minimum distance of fastener to edge of 35mm.
ExpressWall Vertical Gasket
ExpressWall screws each side of top hat
ExpressWall Top Hat
100mm min.
50mm
Backing Strip
100mm min.
ExpressWall Vertical Gasket
Backing Strip
Screw Spacing (refer Table 5)
CEMINTEL EXPRESSWALL™ 23
SCREW HEAD COVERING FOR COUNTERSUNK SCREWS
Allcountersunkscrewheadsmustbecoveredwithepoxycompound and flush finished with the ExpressPanel™ face.
Epoxy shall be installed in the following manner:• Mixepoxyaccuratelyinaccordancewiththe
packaging/manufacturer’sinstructions.• Immediatelyusemixedepoxy.• Avoidoverfillingholes,andleveloffbeforeepoxy
fully cures.• AthinlayerofCemintel™ External Joint Compound may
be used to achieve a flush finish.
FIG 34: Epoxy Covering of Screw Heads
HINT:Onewayofapplyingepoxyisthrougha20mmholeinthinmetalsheet(0.6mmorless)orothersuitablematerial.This will minimise spill‑over and allow for some shrink back of the epoxy without having to repeat the application.
ExpressWall Screw
Screw head covered with epoxy
Top Hat
ExpressPanel
Thin metal strip or other appropriatematerial
ExpressWall Screw
ExpressPanel
Cover screw head andfill hole with Epoxy
24 CEMINTEL EXPRESSWALL™
CuRvED FACADESCemintel ExpressPanel™andBareStone™ panels can be curvedtoaminimumradiusof10m.Theframingmustbesetout to a true curve to enhance appearance and avoid over‑stressingthesheetandfixings.MaximumtophatspacingsaretobeinaccordancewithTable6,orcloserifrequiredforwind loads.
TABLE 6: Curved Wall Framing and Facade Panel
Curve Radii(m
MaximumTopHatSpacing(mm)
Panel Width900mm
Panel Width1200mmor
Greater
10m-15m 300* 400*
>15m 450 600
*Provide2additionalfixingspermetretoeachtophat.
CEMINTEL EXPRESSWALL™ 25
CoNSTRuCTIoN DETAILSFIG 35: Deflection Head with Expressed Joint
FIG 36: Deflection Head with Filled Joint
WALL FLASHINGSIn general, flashings shall be designed and installed in accordancewithSAA–HB391997–InstallationCodeforMetalRoofingandWallCladding.Stopendsshallbeincorporatedwithallflashings.Allflashingsaresuppliedbyothers.
TABLE 7: Flashing Upstand
Ultimate Design Wind Pressure (kPa)
FlashingUpstandMinimum (mm)
2.5 150
3.5 200
4.0 250
5.0 300
6.0 350
7.0 400
FIG 37: Base Detail for Inline Slab
FIG 38: Base Detail Corrosivity Category D - Inline Slabt
Angle fixed to Top Hat
Sarking
Drip groove Soffit
Backing Rod
Panel
Top Hat
Deflection gap to be specified by project engineer
Support Framing
Continuous bead of sealant between sheet and angle
Sealant depth 12mm min. or 50% of gap height
Concrete footing
Sealant
Sarking
Flashing
Flashing Tape
Panel
Open joint to allow moisture to escape
Flashing upstand (refer to Table)
ExpressWall Top Hat
Steel Frame
Girt Supports to Engineers Details
Angle fixed to Top Hat
Drip groove
Soffit
Backing Rod
Panel
Top Hat
Deflection gap to be specified by project engineer
Support Framing
Continuous bead of sealant between sheet and angle
Sarking
Sealant depth 12mm min. or 50% of gap height
Concrete footing
Sealant
Sarking
Flashing
Flashing Tape
Panel
100mm max.
Open joint to allow moisture to escape
Flashing upstand (refer to Table)
ExpressWall Top Hat
Cemintel™ Cavity Baffle
Steel Frame
Girt Supports to Engineers Details
Angle fixed to Top Hat
Sarking
Drip groove Soffit
Backing Rod
Panel
Top Hat
Deflection gap to be specified by project engineer
Support Framing
Continuous bead of sealant between sheet and angle
Sealant depth 12mm min. or 50% of gap height
Concrete footing
Sealant
Sarking
Flashing
Flashing Tape
Panel
Open joint to allow moisture to escape
Flashing upstand (refer to Table)
ExpressWall Top Hat
Steel Frame
Girt Supports to Engineers Details
Angle fixed to Top Hat
Drip groove
Soffit
Backing Rod
Panel
Top Hat
Deflection gap to be specified by project engineer
Support Framing
Continuous bead of sealant between sheet and angle
Sarking
Sealant depth 12mm min. or 50% of gap height
Concrete footing
Sealant
Sarking
Flashing
Flashing Tape
Panel
100mm max.
Open joint to allow moisture to escape
Flashing upstand (refer to Table)
ExpressWall Top Hat
Cemintel™ Cavity Baffle
Steel Frame
Girt Supports to Engineers Details
Angle fixed to Top Hat
Sarking
Drip groove Soffit
Backing Rod
Panel
Top Hat
Deflection gap to be specified by project engineer
Support Framing
Continuous bead of sealant between sheet and angle
Sealant depth 12mm min. or 50% of gap height
Concrete footing
Sealant
Sarking
Flashing
Flashing Tape
Panel
Open joint to allow moisture to escape
Flashing upstand (refer to Table)
ExpressWall Top Hat
Steel Frame
Girt Supports to Engineers Details
Angle fixed to Top Hat
Drip groove
Soffit
Backing Rod
Panel
Top Hat
Deflection gap to be specified by project engineer
Support Framing
Continuous bead of sealant between sheet and angle
Sarking
Sealant depth 12mm min. or 50% of gap height
Concrete footing
Sealant
Sarking
Flashing
Flashing Tape
Panel
100mm max.
Open joint to allow moisture to escape
Flashing upstand (refer to Table)
ExpressWall Top Hat
Cemintel™ Cavity Baffle
Steel Frame
Girt Supports to Engineers Details
Angle fixed to Top Hat
Sarking
Drip groove Soffit
Backing Rod
Panel
Top Hat
Deflection gap to be specified by project engineer
Support Framing
Continuous bead of sealant between sheet and angle
Sealant depth 12mm min. or 50% of gap height
Concrete footing
Sealant
Sarking
Flashing
Flashing Tape
Panel
Open joint to allow moisture to escape
Flashing upstand (refer to Table)
ExpressWall Top Hat
Steel Frame
Girt Supports to Engineers Details
Angle fixed to Top Hat
Drip groove
Soffit
Backing Rod
Panel
Top Hat
Deflection gap to be specified by project engineer
Support Framing
Continuous bead of sealant between sheet and angle
Sarking
Sealant depth 12mm min. or 50% of gap height
Concrete footing
Sealant
Sarking
Flashing
Flashing Tape
Panel
100mm max.
Open joint to allow moisture to escape
Flashing upstand (refer to Table)
ExpressWall Top Hat
Cemintel™ Cavity Baffle
Steel Frame
Girt Supports to Engineers Details
26 CEMINTEL EXPRESSWALL™
FIG 39: Framed Soffit Detail
FIG 40: Abutment Detail – Option 1
FIG 41: Abutment Detail – Option 2
FIG 42: Abutment Detail – Option 3
Sarking
10mm min.
Sealant
Wall
100mm max.
40mm min.
Backing Rod
Top Hat Continuous bead of sealant
Angle 1mm galvanised steel by others
100mmmax.
10-20mm gap
Panel
Top Hat Angle 1mm galvanised steel by others
Sealant
Wall
Backing Rod
Continuous bead of sealant
Sarking
10-20mm gap
Panel
Sealant
Wall
Backing Rod
Sarking
Continuous bead of sealant
10-20mm gap
Top Hat Angle 1mm galvanised steel by others
Panel
Panel
Top Hat
Flashing behind tophat(refer to upstand Table)
Soffit lining
100mmMax.
30-50mm
Sarking
Flashing Tape
Soffit Casing Bead
CEMINTEL EXPRESSWALL™ 27
FIG 43: Internal Corner Detail
FIG 44: External Corner Detail
Intermediate Top Hat
Rigid structure at corners
Intermediate Top Hat
Angle 1mm galvanised steel by others
Continuous bead of sealant
Top Hat spacing
Top Hat spacing
Sarking
10mm nom.
Panel
Rigid structure at corners
Intermediate Top Hat
Intermediate Top Hat
Sarking
SarkingContinuous bead of sealant
Top Hat spacing
Top Hat spacingSupport Framing
Support Framing
Angle 1mm galvanised steel by others
10mm nom.
Panel
Panel
28 CEMINTEL EXPRESSWALL™
FIG 45: Curved Corner Detail
FIG 46: Angled Corner Detail
Top Hat fixed to frame to engineer's detail
Support Framing
Support Framing
Sarking
10mm nom.
10mm nom.
Corner panel supplied by others
Intermediate Top Hat
Continuous bead of sealant
Sarking
Maximum 50% of Top Hat spacing
Rigid structure at corners
Support Framing
Support Framing
Intermediate Tophat
Maximum 50% of Top Hat spacing
Angle 1mm galvanised steel supplied by others
Panel
CEMINTEL EXPRESSWALL™ 29
FIG 47: Capping Detail – Option 1
Parapet capping shall be designed and fastened in accordancewithSAA–HB391997–InstallationCodeforMetalRoofingandWallCladding.Stopendsshallbeincorporated to all flashings.
TABLE 8: Capping Overlap
Ultimate Design WindPressure
(kPa)
MinimumCapping Overlap
(mm)
1.5 50
3.5 100
5.0 150
7.0 200
FIG 50: Vertical Control Joint
FIG 48: Capping Detail – Option 2
FIG 49: Horizontal Control Joint
Cap
ping
ove
rlap
(refe
r to
Tabl
e)
Sarking
30mm min.
Fall
Subframe member
Hardwood support
Top Hat
Clip to suit capping fixed through oversize hole in panel
Panel
Sarking
Fall
Bead of sealant
ExpressWall Backing Strip
Subframe member
Hardwood support
Top Hat
Gasket to extend to top of ExpressPanel
Screw fix capping to backing strip over continuous bead of sealant
Panel
Flashing
Top Hat
Sealant
Rivet as required
Rivet as required
Rivet
10mm
10mm overlap Anticipated movement +5mm
Anticipated movement +5mm
10mm 10mm
20mm
Continuous bead of sealant
Continuous bead of sealant
Flashing behind top hat(refer to Flashing Upstand Table)
Panel
Panel
Sarking
Fall
Bead of sealant
ExpressWall Backing Strip
Subframe member
Hardwood support
Top Hat
Gasket to extend to top of ExpressPanel
Screw fix capping to backing strip over continuous bead of sealant
Panel
Flashing
Top Hat
Sealant
Rivet as required
Rivet as required
Rivet
10mm
10mm overlap Anticipated movement +5mm
Anticipated movement +5mm
10mm 10mm
20mm
Continuous bead of sealant
Continuous bead of sealant
Flashing behind top hat(refer to Flashing Upstand Table)
Panel
Panel
Movement joint in structure to engineer's specifications
.xam mm001 .xam mm00110-20mm nom. joint
Continuous bead of sealant
Sealant Top Hat Top Hat Continuous bead of sealant
Galvanised steel angles Backing Rod
Panel Panel
30 CEMINTEL EXPRESSWALL™
FIG 51: Window Head Detail
FIG 52: Window Sill Detail
Panel
Flashing (refer to Flashing Upstand Table)
NOTE: Use Cavity Baffle in Corrosivity Category C4
Flashing Tape
Gap to allow water to drain over flashing
Continuous bead of sealant
Sarking
Air seal
ExpressWall Top Hat
Window Frame
Support Framing
Support Framing
Window Frame
ExpressWall Top Hat
Continuous bead of sealant
Sarking
Air seal
Panel
CEMINTEL EXPRESSWALL™ 31
FIG 53: Window Jamb Detail Option 1
FIG 54: Window Jamb Detail Option 2
FIG 55: Window Jamb Detail Option 13
Continuous bead of sealant10mm nom.
Sealant 10mm depth Flashing
SarkingBacking Rod
Air Seal
Window Frame
Panel
Panel
Sarking
Continuous bead of sealant
Flashing10mm nom.
Air Seal
Window Frame
Continuous bead of sealant
10mm nom.
Continuous bead of sealant
Sealant 10mm depth Flashing
SarkingBacking Rod
Air Seal
Window Frame
Panel
32 CEMINTEL EXPRESSWALL™
WINDOW FLASHING PROCEDUREThe installation of window flashings will depend on the chosen windows and framing methods. The following details show a typical installation procedure.
FIG 56: Typical Window Flashing Procedure
ExpressWall Tophat
Framing
Window frame
STEP 1Install Metal Head Flashing(refer to Flashing Upstand Table)
STEP 2 Install continuous bead of sealant
Continuous bead of sealant behind flashing
Window frame
STEP 7Fill joint with sealant
STEP 6Install Backing Rod
Window frame
STEP 9Install continuousbead of sealant
STEP 8Install ExpressWallVertical Gasket
STEP 10Install Panel
Window frame
Window frame
STEP 3Install Metal Flashing(refer to FlashingUpstand Table)
Window frame
STEP 5Install Metal Flashing
STEP 4Install Intermediate Tophat
CEMINTEL EXPRESSWALL™ 33
FIRE RATED WALL SySTEMSCemintel ExpressWall™ can be used with a variety of CSR Gyprock and Fibre Cement fire rated wall systems.
These can provide a fire rating from one or both sides of the wall depending upon the internal lining materials chosen.
FRL
– / – / –
CSR 933
Rw 25
External Side of Wall Framing
•1layerCemintelExpressPanel™orBareStone™ panels fixed to Cemintel ExpressWall™ top hatframing system.
•Sarking. Internal Side of Wall Framing
•Nil.
WALLWIDTH(excludingwallframe)mm 44
FRL60/60/60
fromoutside of the wall
only
report/opinion
FAr 2357
CSR 934
Rw 38
External Side of Wall Framing
•1layerCemintelExpressPanel™orBareStone™ panels fixed to Cemintel ExpressWall™ top hat framing system.
•Sarking.
•2layersx16mmGYPROCKFYRCHEKMRplasterboard fixedtoframingspacedat600mmmaximumcentres.
Internal Side of Wall Framing
•Nil.
WALLWIDTH(excludingwallframe)mm 76
note:For additional fire and acoustic systems, please refer to the csr gyprock Fire & Acoustic Design guide, nºgyp500
Refer to the system tables for detailed information.
For detailed information on fixing fire rated linings, refer to theCSRGyprockFire&AcousticDesignGuide,NºGYP500.
34 CEMINTEL EXPRESSWALL™
FRL60/60/60
fromoutside of the wall
only
report/opinion
FAr 2357
CSR 935
Rw 41 – 48
External Side of Wall Framing
•1layerCemintelExpressPanel™orBareStone™ panels fixed to Cemintel ExpressWall™ top hat framing system.
•Sarking.
•1layerx16mmGYPROCKFYRCHEKMR plasterboard fixed to framing.
•Steelstudframingasrequired.
Internal Side of Wall Framing
•1layerx16mmGYPROCKFYRCHEK plasterboard fixed to framing.
STUDDEPTH
92 150
CAVITYINFILL Rw
(a)Nil 41 44
(b)R1.5BradfordGoldBatts 46 48
(c)ASB4/TSB4PolyesterBatts 46 48
WALLWIDTHmm 168 226
FRL60/60/60
fromoutside of the wall
only
report/opinion
FAr 2303
CSR 905
Rw 41 – 46
External Side of Wall Framing
•1layerCemintelExpressPanel™orBareStone™ panels fixed to Cemintel ExpressWall™ top hat framing system.
•Sarking.
•1layerx16mmGYPROCKFYRCHEKMRplasterboard fixed to framing.
•Timberstudframingasrequired.
Internal Side of Wall Framing
•1layerx10mmGYPROCKplasterboardCDfixedtoframing.
STUDDEPTH
92
CAVITYINFILL Rw
(a)Nil 41
(b)R1.5BradfordGoldBatts 46
(c)ASB4/TSB4PolyesterBatts 45
WALLWIDTHmm 160
note: *load limits Apply For additional fire and acoustic systems, please refer to the csr gyprock Fire & Acoustic Design guide, nºgyp500.
CEMINTEL EXPRESSWALL™ 35
FIG 57: Typical ExpressWall™ Fire Rated Installation. (FRL 60/60/60 from outside only)
2 x 16mm Gyprock Fyrchek MR Plasterboard
Refer to Capping Details
Concrete slab
ExpressPanel™ or BareStone™
Sarking
Ground clearance to regulatory requirements
Gyprock Fire Mastic to depth of outer plasterboard layer
Gyprock Fire Mastic to depth of outer plasterboard layer
Top Hat
Roofing
Angle (50 x 50 x 0.75mm BMT gal MS) mechanically fastened to concrete at 600mm max. centres and seal to slab
Refer to base flashing detail
Sarking
36 CEMINTEL EXPRESSWALL™
FIG 58: Typical ExpressWall™ Fire Rated Installation (FRL 60/60/60 from outside only).
16mm GYPROCK FYRCHEK MR Plasterboard
Non-combustible eaves lining (eg. CSR Fibre Cement Eaves Lining Sheet)
CSR Bradford Fibertex Rockwool
Timber blocking (45mm min. thickness) to form fire barrier
10mm GYPROCK plasterboard CD
10mm GYPROCK plasterboard CD
Concrete slab
ExpressPanel™ or BareStone™
Sarking
Top Hat
Control joint in ExpressWall (refer to detail)
Control joint in plasterboard (15mm high) filled with Gyprock Fire Mastic
Ground clearance to regulatory requirements
Refer to base flashing detail
Gyprock Fire Mastic
CEMINTEL EXPRESSWALL™ 37
ARCHITECTuRAL SPECIFICATIoN
SCOPEThe contractor shall furnish all materials, labour and equipment for the installation of the Cemintel ExpressWall™ Systemwhereindicatedonthedrawingsand/orasspecified.
The ExpressWall™ system shall be installed in accordance withCSRguideNºFC126CemintelExpressWall™.
CLADDING MATERIALSCladding material shall be Cemintel ExpressPanel™ or CeminSealBareStone™ Panel as manufactured by CSR.
ExpressPanel™ shall be 9mm compressed cellulose reinforcedsheetmanufacturedinaccordancewithAS/NZS2908.2.BackfaceissealedwithVC-9,aUVcuredhighbuildclearsealerappliedtoathicknessof35-40µm.FrontfaceofpanelsisundercoatedwithVC-7,aUVcuredhighbuildwhitesealerappliedtoathicknessof35-40µm.FinalcoatisVP-200whiteIntercoatprimerwithathicknessof5-10µmto front face and edges.
CeminSealBareStone™ Panel shall be 9mm compressed cellulose reinforced sheet, incorporating waterblock technology,manufacturedinaccordancewithAS/NZS2908.2.
EXPRESSWALL™ STEEL FRAMINGCeminte l ExpressWal l™ steel f raming system shal l be Cemintel ExpressWall™ TopHat of....................... BMTassuppliedbyCSR,andIntermediateTopHatasmanufacturedbyRondoBuildingServicesPtyLtd.FramingshallbeinstalledinaccordancewithCSRguideNºFC126Cemintel ExpressWall™.
SARKINGSarkingmaterialshallbe*Bradford....................................... ...................................................or product of equivalent or better performance).
CAVITY INFILL INSULATIONCavityinfillshallbe*Bradford...................................(orproductof equivalent or better performance).
FLASHINGSFlashings not supplied by CSR shall be designed and installedinaccordancewithSAA–HB39,1997,InstallationCodeforMetalRoofingandWallCladding.Flashingtobecolour matched to the panels.
FIXINGSScrews for f ixing ExpressPanel™ to top hats shall be ExpressWallCountersunkHeadScrews,Class3finishassuppliedbyCSR.AllcountersunkheadscrewsintheExpressPanel™‚shallbecoveredwith*.....................epoxy,and sanded flush with the panel surface.
OR
Screws for fixing ExpressPanel™/BareStone™ Panel to tophatsshallbeExpressWallExposedHeadScrews, *Class3 f inish/*StainlessSteelassuppliedbyCSR.ExpressWall™ Weather Seal shall be used with all exposed headscrews.*Exposedheadscrewsshallbecolourmatchedto the panels.
ACCESSORIESTapes, gaskets, sealants, backing strips and the like shall be asdetailedinCSRguideNºFC126CemintelExpressWall™.
COATINGSExpressPanel™/BareStone™ Panels shall be coated with *..........................,colour*.......................,whichshallbeinstalledto the manufacturer’s recommendations.
FIRE RATED WALL SYSTEMThe contractor shal l supply and instal l wall system *NºCSR...............inaccordancewithCSRGyprockFire&AcousticDesignGuide,NºGYP500.ThewallshallhaveaFireResistanceLevel*FRL...../...../.....inaccordancewiththerequirementsofAS1530.4.Installationshallalsobecarriedout to the level specified for an acoustic performance of *Rw...........usingcavityinfillof*Bradford...............................
FRAMING, FIXING & JOINTS.AllExpressWall™ framing, fixing and joints shall be designed and installed to comply with the requirements for an Ultimate DesignWindPressureof*............kPaminimum.
note: *insert or select appropriate product/information.
38 CEMINTEL EXPRESSWALL™
MATERIAL PRoPERTIES
FIRE RESISTANCEUndertheBuildingCodeofAustralia,ClauseC1.12(d),Cemintel™ fibre cement is deemed to be non‑combustible. WhentestedinaccordancewithAS1530.3,theEarlyFireHazardIndicesareasfollows:
ExpressPanel™ & BareStone™ Manufacturing Tolerances
Length +0to-2mm.
Width +0to-2mm.
Thickness +10%to-0%.
Diagonals Difference (max) 2mm
Edge Straightness deviation (max 1mm
Physical Properties
Property
Cemintel™ Compressed Sheet
atEMC* Saturated
Thickness 1700 1900
Flexural Strength (characteristic)
Parallel to sheet length
-ultimate(MPa)2520
-yield(MPa)2013
Parallel to sheet width
-ultimate(MPa)2016
-yield(MPa)
25
20
20
17
20
13
16
12
ModulusofElasticity(GPa) 10 9
Thermal Expansion Coefficient 10x10-6/K° (est. average)
MoistureMovement
-fromEMC*tosaturated
-from30to90%RH (toASTMC1185)
-700Microstrains (expansion)
-500Microstrains (expansion)
note: * emc (equilibrium moisture content) is at nominally w23°c and 50% relative Humidity environment conditions.
FIRE RESISTANCEUndertheBuildingCodeofAustralia,ClauseC1.12(d),Cemintel™ fibre cement is deemed to be non‑combustible. WhentestedinaccordancewithAS1530.3,theEarlyFireHazardIndicesareasfollows:
SYSTEM TESTINGThe Cemintel ExpressWall™ System has been designed and tested by CSR Gyprock & Fibre Cement Research & Development. The ExpressWall™ System has passed testingtothefollowingpartsofAS/NZS4284-1995TestingofBuildingFacades.
•StructuralTest.•WaterPenetrationbyStaticPressure.•WaterPenetrationbyCyclicPressure.•ProofTest.
ThesystemhasbeentestedtoAS4040.3-1992Methodsoftestingroofandwallcladding,Method3:Resistancetowindpressure for cyclonic regions.
CEMINTEL EXPRESSWALL™ 39
HANDLINg & SToRAgEAllCemintelExpressPanel™andBareStone™ panels must be stacked flat, clear of the ground, and supported on a level platform.
Care must be taken to avoid damage to edges, ends and surfaces.
Materialmustbekeptdry,preferablybybeingstoredinside the building. Protect from contaminants such as silicone spray.
Where it is necessary to store panels outside, they must be protected from the weather.
Panels must be dry prior to fixing and finishing.
SAFETyWhen cutting panels using power tools, always ensure the workareaiswellventilated.Anapproveddustmask(AS1715andAS1716)andsafetyglasses(AS1337)mustbeworn.CSRrecommends that hearing protection be worn.
PANEL CuTTINg
POWER SAWWhen it is necessary to use power tools for cutting panels, CSRrecommendsusingtheHitachiFibreCementPowerSawBlade.Thisbladeisspecificallydesignedforusewithfibre cement and produces a superior cut compared to conventional blades.
ItisidealforusewiththeHitachiC7YAdustlesscircularsawandother185mmcircularsawsfittedwithvacuumextractionsystems.
DRILLINGCountersunk holes in Cemintel ExpressPanel™ shall be drilled and countersunk with the recommended countersinking tool. Allgeneralpurposedrillingofpanelsshallbedonewithamasonry drill bit.
note: in all cases Do not use hammer action when drilling.
Hitachi c7yA Dustless circular saw with Dust extraction system.
Hitachi Fibre cement power saw Blade.
EXPRESSWALL FC:126
CONTACT DETAILS
www.CEmINTEL.COm.Au
Cem
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HealtH & Safety
WaRNINGFibre Cement products contain crystalline silica. Repeated inhalation of fibre cement dust may cause lung scarring (silicosis) or cancer. Do not breathe the dust. When cutting sheets, use the methods recommended in this brochure to minimise dust generation. If power tools are used, wear an approved dust mask (respirator). These precautions are not necessary when stacking, unloading or handling fibre cement products.
For furtherinformation and for a Material Safety Data Sheet, phone 1800 807 668.
GuaRaNteeCSR Building Products Limited (“CSR”) warrants its Cemintel ExpressPanel™ and Barestone™ panels (“Product”) to remain free of defects in material and manufacture for 10 years from date of purchase.
In the event of any failure of the Product caused by the direct result of a defect in the material or manufacture of the Product, CSR will at its option replace or repair, supply an equivalent product, or pay for doing one of these.
This warranty does not apply where the Product has been used in any manner not in accordance with the manufacturer’s instructions, nor the reuse of the Product after its initial installation. CSR recommends that only those products, components and systems recommended by it be used. CSR wil l need to be satisfied that any defect in its Product is attributable to material or manufacture defect (and not another cause) before this warranty applies.
Other than as expressly set out in this warranty, and the guarantees that cannot be excluded under The Australian Consumer Law (Schedule 2 of the Competition and Consumer Act 2010 (Cth)) (and any other law), CSR excludes all other warranties and guarantees with regard to the Product including all guarantees and warranties that may apply at law.
To the extent that it is able to do so, CSR excludes all liability for loss and damage (including consequential loss) in connection with the Product. This exclusion does not apply where the Product is sold to a consumer and is a good of a kind ordinarily acquired for personal, domestic or household use or consumption.
The following statement is provided where the Product is supplied to a buyer who is a “consumer” under the Australian Consumer Law: Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure. The benefits of this warranty are in addition to other rights or remedies of the consumer under law in relation to the goods or services to which the warranty relates.
Notification of a warranty claim must be made to CSR prior to any return of the Product.
To make a claim under this warranty, you must contact CSR on 1300 CEMINTEL. All expense of claiming the warranty will be borne by the person making the claim. CSR may require documentation supporting the claim to be provided.
AuGuST 2012
CSR Cemintel™ Sales Support Tel: 13 17 44 Fax: 1800 646 364
CSR designLINK® Technical Support Service Tel: 1800 621 117
New South Wales and ACT 376 Victoria Street, Wetherill Park NSW 2164
Queensland 768 Boundary Road, Coopers Plains QLD 4108
Victoria 277 Whitehall Street, Yarraville VIC 3013
South Australia Lot 100 Sharp Court, Mawson Lakes SA 5095
Western Australia 21 Sheffield Road, Welshpool WA 6106
Tasmania PO Box 61, Glenorchy TAS 7010
Northern Territory Cnr Stuart Hwy & Angliss St, Berrimah NT 0828
Cemintel™, ExpressWall™, ExpressPanel™, BareStone™ & CeminSeal™ are trademarks of CSR Limited.