AUSTRALIAMARCH 2009

INSTALLATION MANUAL

CERAMIC TILE UNDERLAYVINYL AND CORK UNDERLAY

1 INTRODUCTION

James Hardie manufactures three types of fibre cement underlays for useunder tiles, vinyl and cork in flooring applications. All of these JamesHardie underlays come with a pre-marked nailing pattern and are suitablefor use over internal timber, particle board or plywood floors in wet anddry areas.

Ceramic tile underlay is a larger underlay sheet with pre-marked nailingpattern on the face. Its main features are:

Larger board size is ideal for bigger bathrooms and large floor areasbeing tiled.

Sealer increases cement based tile adhesive working time by 50%.

Can be used in wet and dry areas.

Durable and reliable.

Minimises tile movement, reducing the potential for tile cracking.

Vinyl and cork underlay is a pre-marked sheet which provides a smoothbase for vinyl and cork flooring finishes.

The specifier or other responsible party for the project must ensure theinformation and details in this guide are appropriate for the intendedapplication and that specific design and detailing is undertaken for areaswhich fall outside the scope of this documentation.

Make sure your information is up to dateWhen specifying or installing James Hardie products, ensure you have thecurrent manual. If you’re not sure you do, or if you need more information,visit www.jameshardie.com.au or Ask James Hardie™ on 13 11 03.

CONTENTS1 INTRODUCTION 2

2 SAFE WORKING PRACTICES 4Warning 4Recommended safe working practices 4Working instructions 4Hole-forming 5Storage and handling 5Quality 5

3 PREPARATION 6General 6Underfloor ventilation 6Existing timber floors 6Substrate preparation 6

4 INSTALLATION 7Installation steps 7Additional requirements for vinyl and cork underlay 8

5 MOVEMENT JOINTS 9

6 FINISHES 9General 9Slate floor tiles 9Marble floor tiles 9

7 MAINTENANCE 10

8 PRODUCT INFORMATION 10General 10Product mass 10Durability 10

9 WARRANTY 11

WE VALUE YOUR FEEDBACKTo continuously improve the development of our products andsystems, we value your input. Please send any suggestions,including your name, contact details, and relevant sketches to:

Ask James Hardie™

Fax 02 9638 9535literaturefeedback@jameshardie.com.au

Tiles

Tile adhesive

James Hardieunderlay

JH stud adhesive

Floor substrate

JAMES HARDIE UNDERLAYS INSTALLATION MANUAL DECEMBER 2008 3

TABLE 1

TABLE 2

PRODUCT / ACCESSORIES / TOOLS

COMPONENTS SUPPLIED BY JAMES HARDIE

ACCESSORIES DESCRIPTION ACCESSORIES DESCRIPTION

Score and snap knifeScoring tool for easy cutting

COMPONENTS NOT SUPPLIED BY JAMES HARDIEJames Hardie recommends the following products for use in conjunction with its underlay products. James Hardie does not supply these products and doesnot provide a warranty for their use. Please contact the component manufacturer for information on their warranties and further information on their products.

ACCESSORIES DESCRIPTION ACCESSORIES DESCRIPTION

Underlay nails Level/straight edge25mm x 2.5 fibre underlay nails For checking straightness of underlying flooring.

Underlay gun nails Sander27mm x 2.1mm bright steel, annular thread, For sanding uneven underlying flooring.flat head collated nail.C21/27R by DuoFast

Staples Notched trowel22mm length x 5mm wide galvanised or copper For adhesive application to back of James Hardieetched, chisel point, narrow crown staple underlay.- resin coated. Suitable for vinyl and cork only.

Backing rod SealantBacking to be used with sealant in movement Suitable sealant for use in movement joints.joints.

Stud adhesiveUsed for adhering underlay onto particle board or plywood floors in tiled applications. 4 litre / 5.2Kg

JAMES HARDIE UNDERLAYS INFORMATION

PRODUCT DESCRIPTION QUANTITY / SIZE

Ceramic tile underlay Thickness: 6mmFibre cement underlay sheet with pre-marked Width: 1200mmnailing pattern on the face. Length: 1800mmSuitable for ceramic tiles.

Vinyl and cork underlay Thickness: 5mmFibre cement underlay sheet with pre-marked Width: 900mmnailing pattern on the face. Length: 1200mmSuitable for vinyl and cork finishes.

18001200

1200900

2 SAFE WORKING PRACTICES

4 JAMES HARDIE UNDERLAYS INSTALLATION MANUAL DECEMBER 2008

WORKING INSTRUCTIONSRefer to recommended safe working practices before starting any cuttingor machining of product.

Score and snapScore and snap is a fast and efficient method of cutting James Hardiebuilding products using James Hardie’s special tungsten tipped scoreand snap knife.

Preferably score on the face side of the product. Score against a straightedge and repeat the action to obtain adequate depth for clean break –normally one third of sheet thickness. Snap upwards to achieve break.Smooth any rough edges with a rasp.

Hand guillotineMake guillotine cut on the off-cut side of line to allow for the thickness ofthe blade.

FibreshearAn electrically powered, fast, clean and effortless way of cutting JamesHardie building products, especially around curves such as archways.Make fibreshear cut on the ‘off-cut’ side of the line to allow for thethickness of the shear.

WARNING - DO NOT BREATHE DUST AND CUTONLY IN WELL VENTILATED AREAJames Hardie products contain sand, a source of respirable crystallinesilica which is considered by some international authorities to be a causeof cancer from some occupational sources. Breathing excessive amountsof respirable silica dust can also cause a disabling and potentially fatallung disease called silicosis, and has been linked with other diseases.Some studies suggest smoking may increase these risks. Duringinstallation or handling: (1) work in outdoor areas with ample ventilation; (2)minimise dust when cutting by using either 'score and snap' knife, fibrecement shears or, where not feasible, use a HardiBlade® saw blade anddust-reducing circular saw attached to a HEPA vacuum; (3) warn others inthe immediate area to avoid breathing dust; (4) wear a properly-fitted,approved dust mask or respirator (e.g. P1 or P2) in accordance withapplicable government regulations and manufacturer instructions to furtherlimit respirable silica exposures. During clean-up, use HEPA vacuums orwet cleanup methods - never dry sweep. For further information, refer toour installation instructions and Material Safety Data Sheets available atwww.jameshardie.com.au. FAILURE TO ADHERE TO OUR WARNINGS,MATERIAL SAFETY DATA SHEETS, AND INSTALLATION INSTRUCTIONSMAY LEAD TO SERIOUS PERSONAL INJURY OR DEATH.

JAMES HARDIE RECOMMENDED SAFE WORKING PRACTICES

CUTTING OUTDOORS1. Position cutting station so wind will blow dust away from the user or

others in working area.2. Use one of the following methods based on the required cutting rate:

BestScore and snapHand guillotineFibreshear

BetterDust reducing circular saw equipped with HardiBlade® saw bladeand HEPA vacuum extraction.

GoodDust reducing circular saw equipped with HardiBlade® saw blade.

CUTTING INDOORSCut only using score and snap, hand guillotine or fibreshears (manual, electric or pneumatic).Position cutting station in a well-ventilated area.

SANDING/DRILLING/OTHER MACHININGWhen sanding, drilling or machining you should always wear a P1 or P2 dust mask and warn others in the immediate area.

IMPORTANT NOTES1. For maximum protection (lowest respirable dust production), James

Hardie recommends always using “Best” - level cutting methods where feasible.

2. NEVER use a power saw indoors.3. NEVER use a circular saw blade that does not carry the HardiBlade® logo.4. NEVER dry sweep - Use wet suppression or HEPA vacuum.5. NEVER use grinders.6. ALWAYS follow tool manufacturers’ safety recommendations.

P1 or P2 respirators should be used in conjunction with above cuttingpractices to further reduce dust exposures. Additional exposure informationis available at www.jameshardie.com.au to help you determine the mostappropriate cutting method for your job requirements. If concern still existsabout exposure levels or you do not comply with the above practices, youshould always consult a qualified industrial hygienist or contact James Hardie for further information.

Scored edge Straight edge

JAMES HARDIE UNDERLAYS INSTALLATION MANUAL DECEMBER 2008 5

HardiBlade® saw bladeThe HardiBlade® saw blade used with a dust-reducing saw and HEPAvacuum extraction allows for fast, clean cutting of James Hardie fibrecement products. A dust-reducing saw uses a dust deflector or a dustcollector which can be connected to a vacuum system. When sawing,clamp a straight-edge to the sheet as a guide and run the saw base platealong the straight edge when making the cut.

HOLE-FORMINGFor smooth clean cut circular holes:Mark the centre of the hole on the sheet.Pre-drill a pilot hole.Using the pilot hole as a guide, cut the hole to the appropriate diameterwith a hole saw fitted to a heavy duty electric drill.

For irregular holes:Small rectangular or circular holes can be cut by drilling a series of smallholes around the perimeter of the hole then tapping out the waste piecefrom the sheet face.Tap carefully to avoid damage to sheets, ensuring the sheet edges areproperly supported.

STORAGE AND HANDLINGTo avoid damage, all James Hardie building products should be storedwith edges and corners of the sheets protected from chipping.

James Hardie building products must be installed in a dry state andprotected from rain during transport and storage. The product must belaid flat under cover on a smooth level surface clear of the ground toavoid exposure to water, moisture, etc.

QUALITYJames Hardie conducts stringent quality checks to ensure any productmanufactured falls within our quality spectrum. It is the responsibility ofthe builder to ensure the product meets aesthetic requirements beforeinstallation. James Hardie will not be responsible for rectifying obviousaesthetic surface variations following installation.

SUBSTRATE PREPARATIONStep 1 Use a straight edge to check that the floor is not out of level by morethan 1mm over a 1m length.

Step 2 If the floor is warped or cupped the whole floor should be rough sandedbefore the underlay is fixed.

Step 3 Ensure floor substrate and James Hardie underlay sheets are clean ofdust, dirt and grease before fixing underlay sheets.

6 JAMES HARDIE UNDERLAYS INSTALLATION MANUAL DECEMBER 2008

3 PREPARATION

GENERALAll construction must be carried out in accordance with the relevantbuilding regulations and standards. Prior to installation, ensure theexisting flooring and supporting framing is suitable for tiling. Contact yourbuilder, designer or engineer if in doubt. Also check that the flooring isfirmly fixed to floor joists.

UNDERFLOOR VENTILATIONCheck that adequate ventilation exists under all timber floors (especiallynew floors) and that the areas are free from damp.

EXISTING TIMBER FLOORSRemove all existing floor coverings to expose timber flooring. Check floorboards to make sure they are firmly nailed to the floor joist. Loose boardsmust be re-nailed firmly into place.

Floor boards must be reasonably flat for ceramic tile underlay. If theboards are badly warped or cupped the whole floor should be roughsanded before the underlay is fixed.

In the case of vinyl and cork underlay, it’s essential that the floor boardsare flat. If they aren’t, the floor must be rough sanded before the underlayis fixed. It’s recommended that floor sanding be carried out by anexperienced tradesman.

Bearers must be in contact with piers. If they aren’t, they should bepacked to ensure there is no perceivable spring in the floor.

Ensure floor is clean of dust, dirt and grease before fixing underlaysheets.

NOTES1. James Hardie Underlays are suited only as a substrate for tiles on

timber floors. For tiling of walls use Villaboard® lining.2. James Hardie underlays must not to be used on concrete slabs. To

build up height of concrete, purpose-made concrete levellingcompounds are more suitable.

Step 4 Sheets are laid closely in a staggered (brick) pattern. Sheets are laidperpendicular to the direction of flooring substrate, as joins must notcoincide with the joints in the timber floor (minimum offset of 100mm isrequired for sheet flooring substrates). Ensure sheet edges are 3mm backfrom walls. Temporarily fix each sheet with two or three nails or staples toavoid movement.

Step 5 Fix sheets from centre outwards using the pre-marked nailing pattern,driving fasteners flush with sheet surface. When hand nailing use 25mm x2.5mm underlay nails. Staples may be used with vinyl and cork underlayon hardwood floors only. Staples should be driven so that the crownfinishes 0.5mm below the sheet surface.

JAMES HARDIE UNDERLAYS INSTALLATION MANUAL DECEMBER 2008 7

4 INSTALLATION

Step 1 Use a straight edge as a guide when scoring ceramic tile underlay andvinyl and cork underlay as shown.

Step 2 Firmly support sheet near cut while snapping upward to break.For vinyl and cork underlay only, keep cut edges to the outside, i.e. against walls, cupboards, etc.

Step 3 Spread a suitable stud adhesive on the back of the underlay sheet with a3mm notched trowel/spreader paying particular attention to the sheetedges. If fixing to hardwood floors, adhesive is not necessary.

75mm max. 50mm min.from corners

12mm min.from edges

150mm

150 mm

8 JAMES HARDIE UNDERLAYS INSTALLATION MANUAL DECEMBER 2008

Step 6 Apply tile adhesive over James Hardie underlay in accordance withadhesive manufacturer’s recommendations.

Step 7 Install tiles in accordance with tile manufacturer’s recommendations.

ADDITIONAL REQUIREMENTS FOR VINYL ANDCORK UNDERLAYNails or staples can be used on hardwood floors. Only nails should beused on softwood floors. Staples should be driven so that the crownfinishes approximately 0.5mm below the sheet surface. Nails should bedriven absolutely flush with the surface of the sheet. Failure to do this canresult in nail heads showing through floor coverings. Do not damagesheet face with hammer indentations.

Where minor height variations (3mm or less) occur at butt joints, thesemay be levelled out by filling with Ardex Feather Finish (Refer to Ardex formore information) or equivalent, instead of sanding. Ensure this is dryprior to applying the adhesive.

Flush-sand all joints between sheets and the areas created by fastenerswith a belt or rotary sander. The Vinco No. SV25 upright sander andMakita belt sander No.9401 fitted with a No.401 vacuum cleaner arerecommended. Use aluminium oxide or silicone carbide medium gritpapers. All sanders must be fitted with effective dust collection devices –see recommended safe working practices.

Failure to provide an absolutely smooth, ridge and indentation-freeunderlay surface will cause unsightly blemishes to appear on the vinyl orcork floor coverings.

Never dry sweep the sanded floor - vacuum only. Where cork tiles orsheeting are to be laid, reseal sanded areas with Cemstick or Bondcrete.Allow resealed areas to dry before laying the floor covering.

JAMES HARDIE UNDERLAYS INSTALLATION MANUAL DECEMBER 2008 9

Provide movement joints where floor dimensions exceed 5m in one orboth directions or where existing structural joints are located. Positionjoints symmetrically about the centre of the floor as shown below.

Also provide movement joints where there are changes of direction, suchas an L-shaped room, and at doorways where the tiled surface is carriedthrough to the next room as shown.

Leave a gap between underlay sheets and tiles. Place a polyethylenebacking rod in the bottom of the joint between the underlay sheets andtop the joint off with a suitable sealant.

The width of the movement joint should be approximately equal to thewidth of the grout line. It is important that the movement joints be carriedthrough to the top of the floor surface i.e. they should not be covered by tiles.

GENERALJames Hardie underlays must be finished with a suitable floor coveringi.e. ceramic floor tiles, vinyl tiles or sheeting, or cork tiles. For thesuitability and installation requirements of floor coverings, check with themanufacturer.

SLATE FLOOR TILESSlate may be used in much the same way as ceramic tiles. The slateshould not be less than about 9mm thick.

MARBLE FLOOR TILESMarble is a relatively weak material and if used as a flooring materialshould be isolated from structural movement. This can be achieved bymodifying the flooring system to incorporate a fully reinforced mortar bedas shown below. It is recommended that the services of a tradespersonexperienced in the application of marble tiles be obtained.

7 MAINTENANCERegular checks and maintenance of components including sealant, groutand waterproofing must be done as required by the manufacturer.

Certain floor coverings have protective clear coatings which enhance thedurability and prolong the life of such floor coverings. For maintenancerequirements check with both the floor covering and coating manufacturer.

Direction offloorboards

Sheet edgesapproximately3mm from wallsand projections

Movementjoints

Mortar bed 30mm min. thick,reinforced with 50 x 50 x 2.5galvanised wire mesh

Marble tiles fixedto mortar bed withflexible adhesive

Timber flooring

Ceramic tileunderlay

Fortecon/Visqueenslip sheet

NOTE:Allow mortar bedto cure prior to tiling

Movement jointDirection of floorboards

Sheet edgesapproximately 3mmfrom walls and projections

James Hardieunderlay

Flooring

Tile

Tile adhesive

Backing rod

Widthof grout

Sealant

James Hardie studadhesive where required

5 MOVEMENTJOINTS

6 FINISHES

8 PRODUCTINFORMATION

10 JAMES HARDIE UNDERLAYS INSTALLATION MANUAL DECEMBER 2008

GENERALJames Hardie underlays are cellulose fibre reinforced cement buildingproducts. The basic composition is Portland cement, ground sand,cellulose fibre and water.

James Hardie underlays are manufactured to AS/NZS 2908.2 ’Cellulose-Cement Products Part 2: Flat Sheets’ (ISO 8336 ‘Fibre Cement FlatSheets’).

James Hardie underlays are classified Type B, Category 3 in accordancewith AS/NZS 2908.2 ’Cellulose-Cement Products’.

PRODUCT MASSBased on equilibrium moisture content the approximate mass of:

Ceramic tile underlay is 8.1 kg/m2.Vinyl and cork underlay is 6.7 kg/m2.

DURABILITYResistance to moisture/rottingJames Hardie underlays have demonstrated resistance to permanentmoisture induced deterioration (rotting) by passing the following tests inaccordance with AS/NZS 2908.2:

Water permeability (Clause 8.2.2)Warm water (Clause 8.2.4)Heat rain (Clause 6.5)Soak dry (Clause 8.2.5)

Resistance to FireJames Hardie underlays are suitable where non-combustible materialsare required in accordance with C1.12 of the Building Code of Australia.

James Hardie underlays have been tested by CSIRO and are classified asa Group 1 material in accordance with Specification C1.10a of the BCA.

James Hardie underlays have the following early fire hazard indices(tested to AS 1530 Part 3).

NOTES: Zero is the best possible result. The rangeis 0 - 10, except Ignition Index which is 0 - 20.

Resistance to termite attackBased on testing completed by CSIRO Division of Forest ProductsReport Numbers FP349 and FP274, James Hardie fibre cement hasdemonstrated resistance to termite attack.

EARLY FIRE HAZARD INDICES

Ignition index 0

Flame spread index 0

Heat evolved index 0

Smoke developed index 0 - 1

JAMES HARDIE UNDERLAYS INSTALLATION MANUAL DECEMBER 2008 11

9 WARRANTY

James Hardie Australia Pty Limited ("James Hardie") warrants for a periodof 10 years from the date of purchase that the ceramic tile underlay andvinyl and cork underlay (the "Product"), will be free from defects due todefective factory workmanship or materials and, subject to compliancewith the conditions below, will be resistant to cracking, rotting, fire anddamage from termite attacks to the extent set out in James Hardie’srelevant published literature current at the time of installation. JamesHardie warrants for a period of 12 months from the date of purchase thatthe accessories supplied by James Hardie will be free from defects due todefective factory workmanship or materials.

Nothing in this document shall exclude or modify any legal rights acustomer may have under the Trade Practices Act or otherwise whichcannot be excluded or modified at law.

CONDITIONS OF WARRANTYThe warranty is strictly subject to the following conditions:

a) James Hardie will not be liable for breach of warranty unless theclaimant provides proof of purchase and makes a written claim eitherwithin 30 days after the defect would have become reasonablyapparent or, if the defect was reasonably apparent prior toinstallation, then the claim must be made prior to installation;

b) this warranty is not transferable;

c) the Product must be installed and maintained strictly in accordancewith the relevant James Hardie literature current at the time ofinstallation and must be installed in conjunction with the componentsor products specified in the literature. Further, all other products,including coating and jointing systems, applied to or used inconjunction with the Product must be applied or installed andmaintained strictly in accordance with the relevant manufacturer’sinstructions and good trade practice;

d) the project must be designed and constructed in strict compliancewith all relevant provisions of the current BCA, regulations andstandards;

e) the claimant’s sole remedy for breach of warranty is (at JamesHardie’s option) that James Hardie will either supply replacementproduct, rectify the affected product or pay for the cost of thereplacement or rectification of the affected product;

f) James Hardie will not be liable for any losses or damages (whetherdirect or indirect) including property damage or personal injury,consequential loss, economic loss or loss of profits, arising incontract or negligence or howsoever arising. Without limiting theforegoing James Hardie will not be liable for any claims, damages ordefects arising from or in any way attributable to poor workmanship,poor design or detailing, settlement or structural movement and/ormovement of materials to which the Product is attached, incorrectdesign of the structure, acts of God including but not limited toearthquakes, cyclones, floods or other severe weather conditions orunusual climatic conditions, efflorescence or performance ofpaint/coatings applied to the Product, normal wear and tear, growthof mould, mildew, fungi, bacteria, or any organism on any Productsurface or Product (whether on the exposed or unexposed surfaces);

g) all warranties, conditions, liabilities and obligations other than thosespecified in this warranty are excluded to the fullest extent allowed by law;

h) if meeting a claim under this warranty involves re-coating ofProducts, there may be slight colour differences between the originaland replacement Products due to the effects of weathering andvariations in materials over time.

DISCLAIMERThe recommendations in James Hardie’s literature are based on goodbuilding practice, but are not an exhaustive statement of all relevantinformation and are subject to conditions (c), (d), (f) and (g) above.Further, as the successful performance of the relevant system dependson numerous factors outside the control of James Hardie (eg quality ofworkmanship and design) James Hardie shall not be liable for therecommendations in that literature and the performance of the relevantsystem, including its suitability for any purpose or ability to satisfy therelevant provisions of the Building Code of Australia ("BCA"), regulationsand standards.

COPYRIGHT MARCH 2009© JAMES HARDIE AUSTRALIA PTY LTD ABN 12 084 635 558TM AND ® DENOTES A TRADEMARK OR REGISTERED MARKOWNED BY JAMES HARDIE INTERNATIONAL FINANCE BV.