BGC Duraplank External Cladding

BGC Duraplank is designed and manufactured as a plank which is reminiscent of traditional weatherboards both in appearance and installation methods. BGC Duraplank is not subject to decay, rot or white ant damage and is non combustible. The result is a safer, more durable cladding that requiresminimum maintenance.

BGC Duraplank is available with a smooth finish, woodgrain (Douglas Fir) or rusticated texture for that authentic weatherboard look. Duraplank has the strength to withstand the rigours of normal family activities.

Duraplank:

  • Reminiscent of traditional weatherboards.
  • Not subject to decay, rot or white ant damage.
  • Safe and durable.
  • Available in different finishes.
  • Achieves BAL 29 as required in AS3959:2009 – Construction of buildings in bushfire prone areas.

Product Description

BGC Duraplank is general-purpose fibre cement cladding for external applications. It is manufactured as a plank, which is reminiscent of traditional weatherboards both in appearance and installation methods.

Unlike timber weatherboards, Duraplank is not subject to timber rot, decay, or white ant damage. It will not support combustion. The result is a safer, more durable cladding that requires minimum maintenance.

Duraplank is available with a rusticated, smooth or wood grain (Douglas Fir) texture for that authentic timber weatherboard look. At 7.5 mm thick, Duraplank has the strength to withstand the rigours of all normal family activities.

Rusticated

Smooth

Woodgrain

Energy Efficiency Considerations

Energy efficiency requirements have been introduced into the Building Code of Australia (BCA) for both commercial and residential buildings. Thermal heat transfer into and out of the building envelope will effect the running cost of the building and careful consideration of thermal heat transfer needs to be addressed by the architects, engineers and building designers.

Thermal bridging through steel framing will diminish the total R-Value; thermal conductance, of the wall. Thermal breaks are required for steel framed buildings. Thermal break tapes should have a minimum R-Value of 0.2.

Product Information

Duraplank is manufactured from Portland cement, finely ground silica, cellulose fibres and water. Planks are cured in a high-pressure steam autoclave to create a durable, dimensionally stable product.

Duraplank fibre cement products are manufactured to conform to the requirements of AS2908.2 Cellulose-Cement Products and are classified as Type A Category 3 for external use.

Duraplank Size and Mass

THICKNESS (mm) MASS KG/m2 WIDTH mm & PATTERN

LENGTH (mm)

7.5 8.82 205 Rusticated 4200
9.89 230 Smooth & Woodgrain 4200
12.9 300 Smooth & Woodgrain 4200

Plank Tolerances

  • Width +0/-1mm
  • Length +0/-2mm
  • Thickness +10%/-0%
  • Diagonals difference (max) 2mm
  • Edge straightness deviation (max) 1mm

Fire Resistance

BGC Fibre Cement products have been tested in accordance to Australian Standard AS1530.3 – 1989.

These tests deemed the following Early Fire Hazard Indices:

Ignitability Index 0
Spread of Flame Index 0
Heat Evolved Index 0
Smoke Developed Index 0-1

 

Quality Systems

BGC Fibre Cement manufactures Duraplank under the rigorous Quality Management System of the International Standard ISO 9002:1994, and is the holder of Licence Agreement number QEC2955/13.

Handling & Storage

Duraplank must be stacked flat, up off the ground and supported on level equally spaced (max 450mm) gluts.

Duraplank must be kept dry, preferably by being stored inside a building. When stored outdoors it must be protected from the weather.

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

Duraplank must be dry prior to being fixed, or painted. To avoid breakages Duraplank must be carried on edge.

Health and Safety

BGC Duraplank is manufactured from cellulose fibre, finely ground sand, Portland cement and additives. As manufactured, the product will not release airborne dust, but during drilling, cutting and sanding operations cellulose fibres, silica and calcium silicate dust may be released.

Breathing in fine silica dust is hazardous and prolonged exposure (usually over several years) may cause bronchitis, silicosis or cancer.

Avoid Dust Inhalation

When cutting sheets, work in a well-ventilated area and minimise dust generation. If using power tools, wear an approved (P1 or P2) dust mask and safety glasses.

These precautions are not necessary when stacking, unloading or handling fibre cement products.

For further information or a Material Safety Data Sheet contact the nearest BGC Fibre Cement Sales Office.

Quantities Ready Reckoner

Table 1 is provided to assist in calculating the number of planks required to cover a given wall height.

The number of planks required is derived by:

No. of Planks = Numbers of Courses x Wall Length/Plank Length

For example, a wall that is 2400 mm high x 6 m long clad in 230 mm Duraplank with 25 mm overlap, would require 20 planks:

12 Courses x 6 m Wall Length/
4.2 m (Plank Length) = 18 Planks

For triangular areas such as Gable ends, halve the quantities derived for a rectangular wall then add 10% to cover off cuts.

Figure 1 – Plank Course Ready Reckoner

COURSES WALL HEIGHT
205mm PLANK 230mm PLANK 300mm PLANK
25mm OVERLAP 25mm OVERLAP 25mm OVERLAP
1 205 230 300
2 385 435 575
3 565 640 850
4 745 845 1125
5 925 1050 1400
6 1105 1255 1675
7 1285 1460 1950
8 1465 1665 2225
9 1645 1870 2500
10 1825 2075 2775
11 2005 2280 3050
12 2185 2485 3325
13 2365 2690 3600
14 2545 2895 3875
15 2725 3100 4250

Cutting and Drilling

Duraplank may be cut to size on site. If using power tools for cutting, drilling or sanding they must be fitted with appropriate dust collection devices or, alternatively an approved (P1 or P2) dust mask, as well as safety glasses, should be worn.

It is recommended that work be carried out in a well-ventilated location.

The most suitable cutting methods are:

• Durablade180mm diameter. This unique cutting blade is ideal for cutting fibre cement. It can be fitted to a 185mm circular saw, ie Makita or similar. Please ensure safe working practices when using.

• Score and Snap
Score the sheet face 4 or 5 times with a ‘score and snap’ knife. Support the scored edge and snap the sheet upward for a clean break.

• Hand Guillotine
Cut on the off-cut side of the line to allow for the blade thickness.

• Notching
Notches can be made by cutting the two sides of the notch. Score along the back edge then snap upwards to remove the notch.

• Hand Sawing
Duraplanks should be supported close to the cut. A fine toothed saw and a quick jabbing action gives best results. Mark cut lines on face side of the plank.

• Drilling
Use normal high-speed drill bits. Do not use the drill’s hammer function. For small round holes, the use of a hole-saw is recommended.

For small rectangular or circular penetrations, drill a series of small holes around the perimeter of the cut out. Tap out the waste piece from the plank face while supporting the underside of the opening to avoid damage. Clean rough edges with a rasp.

Fasteners

Duraplank must be fastened at every stud (or batten for vertical installations).

Fasteners must not be placed closer than 12 mm from the plank edge.

Nails must not be driven closer than 50 mm from the plank end. Nails or fasteners can be located 20 mm minimum from the plank end if the fastener hole is predrilled.

Except for straight joints, planks must be fixed a maximum of 100 mm from the plank end.

Timber Framing

Duraplank is fixed to timber framing using 40 x 2.8 mm galvanised flat head nails. Nails should be driven flush with the sheet face.

Do not overdrive nails.

Particular care is needed when using nail guns. If variability occurs, the gun should be set to under-drive and the nails tapped home with a hammer.

Nailing should bisect the plank overlap passing through both planks. See Figure 6.

Lightweight Steel Framing

Duraplank is fixed to lightweight steel framing using No.8 x 35 mm galvanised self-embedding head screws. Screws should be driven flush with the sheet face.

Do not overdrive screws.

Screw fasteners should be located 35 mm from the plank edge. See Figure 6.

Coastal Areas

The durability of galvanised nails and screws used for external cladding in coastal or similar corrosive environments can be as low as 10 years. For this reason BGC recommend the use of Stainless Steel fasteners within 1 km of the coast or other large expanses of salt water.

Construction Details

Framing

In general the layouts presented in this publication will be satisfactory for low-rise (up to two storey) domestic and light commercial buildings in non-cyclonic regions.

Buildings in cyclonic regions, high-rise buildings, large industrial and commercial complexes will generally require a specific design to be undertaken. The relevant design details pertaining to Duraplank for various wind classifications, are presented in Figure 1.

Duraplank is suitable for installation on either timber or lightweight steel framing.

Figure 1 – 7.5 mm Duraplank Wall and Gable End Cladding

Timber Framing

Timber framing must be dry prior to fixing Duraplank. If planks are fixed to ‘wet’ framing, problems may occur at a later date due to excessive timber shrinkage.

It is strongly recommended that kiln dried framing is used.

Light Weight Steel Framing

Duraplank may be fixed directly to lightweight steel framing. The steel framing must not exceed 1.6 mm in thickness.

When rigid steel framing is used, it must be battened out with either timber or lightweight steel battens prior to fixing the Duraplanks.

Timber Battens

Timber battens must have a minimum thickness of 40 mm to allow adequate nail penetration.

Steel Battens

Steel battens are typically 50 mm wide on the face x 35 mm deep x 0.75 mm thick

Framing Centres

General

Figure 2 depicts the general framing requirements for Duraplank installed horizontally.

When installing planks vertically, it will be necessary to batten out the framing so that the Duraplank is supported at 600 mm maximum centres.

Sarking

The installation of a vapour permeable perforated sarking between Duraplank and the framing is recommended.

The building’s internal pressure will generally be less than the external air pressure under windy conditions, which will tend to draw water through the planking, flashing and seals if sarking is not used.

Use of a reflective sarking will enhance the insulation properties of the cladding system.

Figure 2 – Duraplank Layout Horizontal Fixing

 

Installation

 

  • Calculate the number of planks required using the Plank Course Ready Reckoner as detailed in Table 1, on page 5.
  • Fix all flashings to wall openings and external and internal corners. See figure 8 for corner details using timber stop ends.
  • Install vapour permeable perforated sarking to manufacturers specifications.
  • Fix a starter strip (timber or a strip of plank) to the bottom plate to ensure the first row of planks are packed out to the correct angle. This starter strip is to be continuous around the perimeters of the building and to overhang the foundation by 50mm. See figure 5 for this detail.
  • Set a horizontal datum line around the perimeter of the building using a string line or spirit level. Fix guide nails/screws along this line to act as a stop for the correct placement of the first course of planks.
  • Duraplank is best suited to be joined off the studs using a metal off stud soaker or PVC jointer. See figures 3 and 4 for these details.
  • Commence fixing the bottom course of plank from an external corner. Fasten the bottom edge of the plank to each stud through the starter strip. Ensure that the plank is level and flush with the corner. Do not nail home the corner fixing at this time.
  • Fit the plank joiner (off stud soaker or PVC joiner) to the end of the plank and continue fixing the bottom course.
  • If using preformed aluminium corners, insert these before nailing home the corner fixing. See figure 7 for this detail.
  • The plank must overlap a minimum of 25mm, and before fixing the second row of planks calculate the overlap so a near full width of plank will finish at the top of the building. Using a piece of timber or plank, fabricate a lap gauge to ensure that the plank coverage is uniform. See figure 9.
  • Commence fixing the second row of planks from an external corner using this lap gauge. Use a shorter length of plank than the bottom course to allow for stagged end joints. See figure 2. Continue fixing the Duraplank around the building following these methods.
  • Fixings must be not be driven closer than 50mm from the end of the plank. For fixings between 20 mm – 50 mm from the end, the plank must be predrilled with a 3mm hole.
  • When fixing woodgrain Duraplank, the pattern is repeated every 4th or 5th plank. To achieve a genuine Douglas Fir pattern, avoid starting each course with a new plank and rotate to avoid pattern repeats.

Figure 3 – Plank Joint Using an Off Stud Soaker

 

Figure 4 – Plank Joint Using a PVC Jointer

Figure 5 – Starter Plank and Ground Clearances

Figure 6 – Fastening Details  

Figure 7 – Light Weight Steel Framing


Installation

Figure 8 – Pre-formed Aluminium Corners

Notes:

  • Cut planks flush with the corner of the framing.
  • Before nailing the plank end, slide in the pre-formed aluminium corner piece so that the tongues fit behind the plank and the bottom edge is flush with the plank.
  • Secure the pre-formed aluminium corner through the hole provided.
  • Securely nail the plank ends.
  • Plank end nails must not be driven closer than 50 mm from the end of the plank. For nail fixings between 20 mm – 50 mm from the end, pre-drill the plank with a 3 mm hole.
  • The sketch depicts an external corner. The method for internal corners is the same except a pre-formed internal corner piece is used.

Figure 9 – Corner Details Using Timber End Stops

Plank Overlaps

Planks must overlap the previous course by a minimum of 25 mm. Higher overlaps may be used to improve weather proofing (particularly when sarking is not used) or to match the wall height to the plank width. For example a 3.0 m high wall clad with 230 mm plank will require 15 courses but a 30 mm overlap matches the wall height better (3030 mm) than a 25 mm overlap (3100 mm) – see Figure 1 on page 5.

The use of a lap gauge, Figure 9, to control sheet overlap will maintain uniformity.

Cutting Around Openings

When cutting planks around window or door openings, a 5 mm nominal clearance must be provided at the jamb, head and sill.

Plank courses should be set out so that as near to a full plank width as possible remains under a window, or similar openings. See Figure 10.

A plank joint at one end for small openings and both ends of longer openings will make installation easier and eliminate breakages.

Flashing and mouldings must be installed as appropriate to prevent ingress of water into the framing.

Figure 11 – Window and Door Openings

Where a plank has been reduced in width, provide a soaker or PVC jointer at one end of the window or door opening. Where openings exceed 1800 mm width, provide a jointer above and below the four corners. Metal jointers should be cut to suit.

Painting

To enhance both the appearance and performance of Duraplank, BGC recommend that at least two coats of an exterior grade paint be applied. The paint manufacturers recommendation on application and maintenance of the paint system should be followed.

Maintenance

Duraplank when used in accordance with this literature requires no direct maintenance.

To guard against water penetrating the structure and damaging the framework, annual inspections of the cladding system should be carried out. Check flashing, sealant joints and paint work.

Flashing and sealants must continue to perform their design function.

Damaged planks should be replaced as originally installed. Paintwork should be maintained in accordance with the manufacturer’s instructions.

Insulation

Duraplank™ cladding will require insulation to be installed in some regions that have thermal loss regulations.

Insulation should be installed in accordance with the manufacturers instructions.

Insulation bats must fit snugly between framing members to minimise heat loss.

Freeze Thaw

Duraplank subject to freeze / thaw conditions must be painted.

Duraplank should not be used in situations where it will be in direct contact with snow or ice for prolonged periods.

Warranty

BGC warrants its products to be free from defects caused by faulty manufacture or materials. If any of its products are so defective the Company will at its option, repair or replace them, supply equivalent replacement products or reimburse the purchase price.

This warranty shall not apply to any loss or consequential loss suffered through or resulting from defects caused by faulty manufacture or materials.

Fittings or accessories supplied by third parties is beyond the control of BGC and as such is not warranted by BGC.

Find Out More

Durasheet Fibre Cement

BGC DuraSheet is designed for the cladding of gable ends, eaves, soffits, car ports and verandah linings of timber and steel framed buildings.

4.5mm thickness is generally used in timber framed residential buildings for soffit linings and the cladding of features such as gable ends. 6.0mm thickness is recommended for commercial applications, cyclonic wind zones and steel framed constructions.

Durasheet

  • Available in two thicknesses to suit both residential and commercial applications.
  • General purpose sheet.
  • 6.0 mm suitable for cylonic wind zones.
  • Classified as Type A Category2 for external use.
  • Can be used on timber and steel framed building.
Product Description

BGC Durasheet is a general-purpose fibre cement sheet for external applications. It is recommended for the cladding of gable ends, eaves, carport and verandah linings of timber or steel framed buildings.

Durasheet is a smooth flat square edged sheet and is manufactured in nominal thickness of 4.5 mm and 6.0 mm.

4.5 mm Durasheet is generally used in timber framed residential buildings for soffit linings and the cladding of features such as gable ends.

6.0 mm Durasheet is recommended for commercial applications, cyclonic wind zones and steel framed construction.

Product Information

Durasheet is manufactured from Portland cement, finely ground silica, cellulose fibres and water. It is cured in a high-pressure steam autoclave to create a durable, dimensionally stable product.

Durasheet fibre cement sheets are manufactured to conform to the requirements of AS2908.2 Cellulose-Cement Products and are classified as Type A Category 2 sheet for external use.

Mass

The approximate weight of Durasheet at equilibrium moisture content (7% moisture) is as tabulated.

NOMINAL THICKNESS (mm) APPROX. WEIGHT (KG/m2)
4.5 7.1
6.0 9.5

Fire Resistance

Durasheet has been tested by the CSIRO – Building, Construction and Engineering Division, in accordance to Australian Standard AS1530.3 – 1989. See report numbers FNE 6966 and FNE 7529.

This report deemed the following Early Fire Hazard Properties:

Ignition Index 0
Spread of Flame Index 0
Heat Evolved Index 0
Smoke Developed Index 0-1

Quality Systems

BGC Fibre Cement manufactures Durasheet under the rigorous Quality Management System of the International Standard ISO 9002:1994, and is the holder of Licence Agreement number QEC2955/13.

Sheet Sizes

THICKNESS LENGTH WIDTH
(mm) (mm) (mm)
450 600 750 900 1200
4.5 1800 x x
2100
2400 x x x x x
2700 x x
3000 x x
6.0 1800 x x
2400 x x
2700 x x
3000 x x

Handling & Storage

Durasheet must be stacked flat, up off the ground and supported on level equally spaced (max 450mm) gluts. The sheets must be kept dry, preferably by being stored inside a building. When stored outdoors they must be protected from the weather.

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

Sheets must be dry prior to being fixed, or painted.
Sheets must be carried on edge.

Health and Safety

BGC Durasheet as manufactured will not release airborne dust, but during drilling, cutting and sanding operations cellulose fibres, silica and calcium silicate dust may be released.

Breathing in fine silica dust is hazardous, prolonged exposure (usually over several years) may cause bronchitis, silicosis or cancer.

Avoid Dust Inhalation

When cutting sheets, use the methods recommended in this literature to minimise dust generation. These precautions are not necessary when stacking, unloading or handling fibre cement products.

For further information or a Material Safety Data Sheet contact any BGC Sales Office.

Sheet Cutting & Drilling

Durasheet may be cut to size on site. If using power tools for cutting, drilling or sanding they must be fitted with appropriate dust collection devices or alternatively an approved (P1 or P2) dust mask and safety glasses should be worn.

It is recommended that work always be carried out in a well-ventilated location.

The most suitable cutting methods are:

Score and Snap

Score the sheet face 4 or 5 times with a ‘score and snap’ knife. Support the scored edge and snap the sheet upward for a clean break.

Hand Guillotine
Cut on the off-cut side of the line to allow for the blade thickness.

Notching
Notches can be made by cutting the two sides of the notch. Score along the back edge then snap upwards to remove the notch.

Drilling
Use normal high-speed drill bits. Do not use the drill’s hammer function. For small round holes, the use of a hole-saw is recommended.

For small rectangular or circular penetrations, drill a series of small holes around the perimeter of the cut out. Tap out the waste piece from the sheet face while supporting the underside of the opening to avoid damage. Clean rough edges with a rasp.

Large rectangular openings are formed by deeply scoring the perimeter of the opening. Next, form a hole in the centre of the opening (refer method above) then saw cut from the hole to the corners of the opening. Snap out the four triangular segments. Clean rough edges with a rasp.

Fasteners

Timber Framing
Durasheet is to be fixed to timber using 30 x 2.0mm galvanised flat head nails. Nails should be driven just flush with the sheet face. Do not overdrive nails.

30×2.0mm Galvanised Flat Head Nail

When using nail guns, if variation occurs the gun should be set to under-drive and the nails tapped home using a hammer.

Lightweight Steel Framing

Use No.8×20 Galvanised wafer head screws for fixing 4.5 mm Durasheet eaves and soffit linings to lightweight steel framing. 4.5 mm Durasheet should not be used for cladding steel framed walls.

No. 8x20mm Galvanised Wafer Head Screw

6.0 Durasheet claddings are fixed to lightweight steel framing using No.8×20 Galvanised self-embedding head screws. Screws should be driven just flush with the sheet face. Do not overdrive screws.

Self-embedding head screws must not be used with 4.5 mm Durasheet.

No. 8x20mm Galvanised Self Embedding Screw

Fixing Requirements

Sheets to be fixed along all sheet edges over studs on wall cladding applications. Fixings centres must not exceed 200 mm for wall cladding and 300 mm for soffit linings.

Do not place fixings closer than 12mm from sheet edges, or closer than 50mm from the sheet corners.

Do not overdrive fasteners.

The sheet must be held firmly against the framing when fixing to ensure breakout does not occur on the back.

Coastal Areas – The durability of galvanised nails and screws used for external cladding in coastal or similar corrosive environments can be as low as 10 years.

For this reason BGC recommend the use of stainless steel or class 3/4 fasteners within 1km of the coast or other large expanses of salt water.

 Sarking

In wall cladding applications the installation of a vapour permeable perforated sarking between Durasheet and the framing is recommended.

Under windy conditions the building’s internal pressure will generally be less than the external air pressure, this will tend to draw water through flashing and seals if sarking is not used.

Use of a reflective sarking will enhance the insulation properties of the cladding system.

Figure 1 – Typical Boxed Eaves Lining

Fixing of Soffits / Eaves Linings

 

The sheet edges must be supported either by nailing at 300 mm maximum centres or by a construction feature such as a grooved fascia board or along an external brick wall.

The sheets may be joined off framing provided PVC joiners are used.

Where sheets are joined off framing, the bearer centres of the span are not to be greater than 450 mm for 4.5 mm Durasheet or 600 mm for 6.0 mm Durasheet.

Where the external walls are to be rendered or texture coated, it is important that a vee joint be created on the coating at the intersection of the Durasheet eave lining and the texture coating on the external wall.

Where a metal roof is installed directly above soffits, severe thermal movement may occur. Where Durasheet is used, it is preferred the roof be vented to allow emission of hot air as well as providing a reduction in roof space temperature.

For eaves to 600 mm maximum width:

  • Soffit bearers must be provided at a maximum of 600 mm centres.

For eaves 600 mm ~ 1200 mm wide:

  • Soffit bearers must be at a maximum of 450 mm

Carport Linings

Typically, when lining a carport with Durasheet, sheets are to be installed at right angles to the ceiling joists using PVC sheetholders to support all sheet joints.

The ends of the sheets should be staggered with a maximum gap of 5.0 mm to facilitate the PVC sheetholder.

The sheets must be nailed at 300 mm maximum centres along each ceiling joist.

The outer sides and ends of perimeter sheets must be supported by framing and nailed at 300 mm maximum centres.

Durasheet must not be fixed directly to the bottom chord of roof trusses. Timber battens or metal furrings should be installed.

Figure 2 – Carport Lining

External Cladding

Framing

  • Framing must be constructed to comply with the Building Bode of Australia.
  • The framing must be set to a true plane to ensure a straight finish to the wall.
  • Studs must be spaced at a maximum of: 450 mm centres for 4.5 mm Durasheet. 600 mm centres for 6.0 mm Durasheet.
  • Noggings must be spaced at a maximum of 1200 mm centres. For horizontal sheet fixing noggings must support the sheet joints.
  • Durasheet cladding must not be joined off the framing.

Timber Framing

Timber framing must comply with AS 1684.2 & .3 -1999 National Timber Framing Code.

Durasheet must not be fixed to wet framing. It is strongly recommended that kiln dried timber is used for framing.

If sheets are fixed to ‘wet’ framing problems may occur at a later date due to excessive timber shrinkage.

Metal Framing

Metal framing must comply with AS 3623 – 1993 Domestic Metal Framing.

Durasheet may be fixed directly to lightweight metal framing. The metal framing must not exceed 1.6 mm in thickness.

If Durasheet is used with rigid steel framing, it must be battened out with either timber or lightweight steel battens prior to fixing.

Timber battens must have a minimum thickness of 40 mm to allow adequate nail penetration. Battens supporting sheet joints must have a minimum actual face width of 45 mm.

Sheet Layout for Cladding

Information in this publication is satisfactory for low-rise (up to two story) domestic and light commercial buildings in non-cyclonic regions.

6.0 mm Durasheet cladding may be fixed vertically or horizontally. However most external cladding is installed vertically. If horizontal joints are used then adequate flashing must be fitted to prevent ingress of water, see Figure 3.

Figure 3 – Horizontal Joint Detail

Notes:

  • Framing must support all sheet joints
  • When sheets are fixed more than one sheet high, vertical joints should be staggered by at least one stud (600mm typical).
  • Durasheet is to be fixed along all sheet edges over studs at 200mm maximum fixings centers.
  • Do not place fixings closer than 12mm from sheet edges or closer than 50mm from sheet corners.

 Wall Abutment

Control Joints must be employed when an addition is constructed onto an existing building or when a masonry wall adjoins a timber or steel framed construction.

Control Joints should be constructed using 9 mm diameter backing rod and polyurethane sealant on abutment to existing masonry walls.

Sheet Joints
Figure 4 – Sheet Joint Light Weight Steel Framing
Figure 5 – Internal Corners PVC Sheet Joinery
Figure 6 – External Corners PVC Sheet Joiners
Ground Clearance

Durasheet must not be used in situations where it will be below ground or where it will be buried in the ground.

A minimum of 100 mm must be maintained from the bottom edge of the sheet to the ground, see Figure7.

Figure 7 – Ground ClearanceBracing

Bracing

BGC 6.0 mm Durasheet can be used to provide bracing to resist racking loads due to wind loadings when installed vertically.

Where Durasheet is used to provide bracing on timber dwellings, the Australian Standard for “Residential timber – framed construction” must be adhered:

AS 1684.2 – 1999 (Non cyclonic areas)
AS 1684.3 – 1999 (Cyclonic areas)

Racking forces due to wind loading shall be calculated as per these Australian Standards.

For bracing data on other construction methods and applications, contact your BGC Fibre Cement Sales Office.

Structural Wall Bracing

The use of 6.0 mm Durasheet is not limited to the provision of nominal wall bracing.

Figure 8 gives the design bracing capacity for panels secured with tie down bolts. This table can be considered to be an addition to Table 8.18, AS1684.2- 1999/AS1684.3 – 1999.

Figure 8 – 6.0 mm Durasheet Bracing Capacity Using Tie Down Bolts

Nominal Wall Bracing

To be eligible for inclusion in calculations as nominal wall bracing:

  • 6.mm Durasheet must be fixed along all sheet edges over studs and top/bottom plates at 200 mm maximum centres.
  • The minimum length of each nominal bracing panel shall be 450mm.
  • Nominal bracing shall be distributed evenly throughout the building.

The Bracing Capacity for nominal bracing is given in the following table.

NOMINAL SHEET BRACING WALLS
METHOD BRACING CAPACITY (kN/m)
Sheeted one side only 0.45
Sheeted two sides 0.75

 Fastener Spacing

When using tie down bolts, fasteners are to be fixed at 150 mm max around sheet perimeter and 200 mm max in the body of the sheet.

STUD CENTRE (mm) CLADDING BRACING CAPACITY (kN/m)ULS*
600 One Face Only 3.0
450 One Face Only 3.15
600 Both Faces 4.28+
450 Both Faces 4.49+

*Ultimate Limit State design.

These results are from testing on JD5 Grade timber.
If hardwood frames (JD2) are used, the ULS will increase by 12.5%.

Permisable Stress Design (PSD) = Ultimate Limit State (ULS)/1.5
+Calculated through interpolation.

Bracing

Figure 9 gives the design bracing capacity for panels secured with anchor rods. This table can be considered to be an addition to Table 8.18, AS1684.2-1999/AS1684.3 – 1999.

Figure 9 – 6.0 mm Durasheet Bracing Capacity Using Anchor Rods

Fastener Spacing

When using tie down bolts, fasteners are to be fixed at 150 mm max around sheet perimeter and 200 mm max in the body of the sheet.

STUD CENTRE (mm) CLADDING BRACING CAPACITY (kN/m)ULS*
600 One Face Only 5.55
600 Both Faces 7.64+

*Ultimate Limit State design.

These results are from testing on JD5 Grade timber. If hardwood frames (JD2) are used, the ULS will increase by 12.5%.

Permisable Stress Design (PSD) = Ultimate Limit State (ULS) / 1.5

+Calculated through interpolation

Panels Height Greater Than 2700mm

The bracing capabilities, Figures 8 and 9 are applicable to a maximum panel height of 2700mm.

For panel heights greater than 2700mm the bracing capacity shall be reduced using the panel height multipler given in the below table.

BRACING CAPACITY – PANEL HEIGHT MULTIPLIER
WALL HEIGHT (mm) MULTIPLIER
3000 0.90
3300 0.80
3600 0.75
3900 0.70
4200 0.64

Panel Length Less Than 900mm

The bracing capabilities, Figures 8 and 9 are applicable to a minimum panel length of 900mm. Effective bracing is achievable with panel lengths down to 450mm. Reduce the bracing capacity for panel between 450mm and 900mm long, using panel length multiplier given in the below table.
BRACING CAPACITY – PANEL HEIGHT MULTIPLIER
WALL HEIGHT (mm) MULTIPLIER
850 0.92

800

0.83

750

0.75

700

0.66

650

0.58
600 0.50
550 0.42
500 0.33
450 0.25

 Wind Loading

The following information is provided to assist in designing for wind loading, in particular for cyclonic areas for 6.0 mm Durasheet.

AS 4055-1992 is applicable to domestic housing. The tabulated data is applicable to all areas and covers the use of both timber and lightweight steel framing.

Design to Queensland Standard

The data presented is equally applicable for use when designing to the Queensland Standard. The following table cross-references the equivalent Wind Classifications.

NON-CYCLONIC CYCLONIC
AS 4055-1992 Queensland  Standard AS  4055-1992 Queensland   Standard
N1 W28N
N2 W33N
N3 W41N C1 W41C
N4 W50N C2 W50C
N5 W60N C3 W60C
N6 W70N C4 W70C

 Design to AS 1170 Part 2-1983

The tabulated data is applicable to Region C (Tropical Cyclone areas) including Darwin and 6.0 mm Durasheet is approved for inclusion in the Darwin Deemed to Comply manual.

  • 6.0 MM Durasheet Wall Cladding – M/222/1 14th November 1997.
  • 6.0 mm Durasheet Soffit Cladding – M/222/2 14th November 1997.

Framing and Fixing Centre Wind Loading – AS 4055 – 1992

Plan View, Eaves & Soffits Linings Framing & Fixing Requirements
Isometric View, Wall Cladding Framing & Fixing Requirements

Freeze Thaw

Durasheet cladding subject to freeze/thaw conditions must be painted.

Durasheet should not be used in situations where it will be in direct contact with snow or ice for prolonged periods.

Painting

To enhance both the appearance and performance of Durasheet, BGC recommend that at least two coats of a water-based paint be applied. The paint manufacturer’s recommendation on application and maintenance should be followed.

Maintenance

when used in accordance with this literature requires no direct maintenance.

To guard against water penetrating the structure and damaging the framework, annual inspections of the cladding system should be carried out. Check flashing, sealant, joints and paint work.

Flashing and sealants must continue to perform their design function. Damaged sheets should be replaced as originally installed.

Warranty

BGC warrants its products to be free from defects caused by faulty manufacture or materials. If any of its products are so defective the Company will at its option, repair or replace them, supply equivalent replacement products or reimburse the purchase price.

This warranty shall not apply to any loss or consequential loss suffered through or resulting from defects caused by faulty manufacture or materials.

Fittings or accessories supplied by third parties is beyond the control of BGC and as such is not warranted by BGC.

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Duratex Fibre Cement

BGC Duratex is designed to provide a solid substrate for applied decorative finishes when combined with proprietary jointing and coating systems.

BGC Duratex provides a tough, durable, waterproof wall cladding system.

Duratex:

  • Is tough and durable
  • Is a waterproof wall cladding system
  • Is fire resistant
  • Ideal for lightweight construction
  • Factory applied blue tint for ease of identification
  • Can be used in residential and commercial applications
  • Accepts a wide range of textured coatings
   

Product Information

Duratex fibre cement sheets are manufactured to conform to the requirements of AS2908.2 Cellulose-Cement Products and are classified as Type A Category 2 sheet for external use.

Mass

The approximate weight of 7.5mm Duratex is 10.28kg/m2 and the approximate weight of 9.0mm Duratex is 12.34 kg/m2.

Appearance

Duratex has a factory applied blue tint sealer on the face of the sheet. This sealer will facilitate the ease of application of the jointing compounds and texture coatings. The sheets are recessed on the two (2) long edges and on one (1) end.

Deemed to Comply

Duratex is approved by the Northern Territory Building Advisory Committee for Darwin Cyclonic Areas as detailed in the Deemed to Comply Manual drawings M/222/3 and M/222/4.

Quality Systems

BGC Fibre Cement manufactures Duratex under the rigorous Quality Management System of the International Standard ISO 9002:1994 and is the holder of Licence Agreement number QEC2955/13.

Sheet Sizes

THICKNESS WIDTH LENGTH
(mm) (mm) (mm)
1800 2400 2440 2728 3000
7.5 900 x x x
1200 x x x x
9.0 1200 x x

 Fire Resistance

BGC Duratex has been tested for and passed the Early Fire Hazard Property criteria in compliance with AS/NZS 1530.3 and AS/NZS 3837 and is deemed a Group 1 Material in accordance with the BCA, Volume 1. Specification A2.4; Fire Hazard Properties. AS/NZS 1530.3; Early Fire Hazard Properties.

This report deemed the following Early Fire Hazard Properties.

  • Ignition Index
0
  • Spread of Flame Index
0
  • Heat Evolved Index
0
  • Smoke Developed Index
0-1

 Handling & Storage

Duratex must be stacked flat, up off the ground and supported on equally spaced (max 300mm) level gluts.

The sheets must be kept dry, preferably by being stored inside a building. When stored outdoors they must be protected from the weather.

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

Sheets must be dry prior to being fixed, jointed or coated. Sheets must be carried on edge.

Health and Safety

BGC Duratex is manufactured from cellulose fibre, finely ground sand, Portland cement and additives. As manufactured, the product will not release airborne dust but, during drilling, cutting and sanding operations cellulose fibres, silica and calcium silicate dust may be released.

Breathing in fine silica dust is hazardous, prolonged exposure (usually over several years) may cause bronchitis, silicosis or cancer.

Avoid Dust Inhalation

When cutting sheets, work in a well-ventilated area and use the methods recommended in this literature to minimise dust generation. If using power tools wear an approved (P1 or P2) dust mask and safety glasses.

These precautions are not necessary when stacking, unloading or handling fibre cement products.

Sheet Cutting & Drilling

Duratex may be cut to size on site. If using power tools for cutting, drilling or sanding they must be fitted with appropriate dust collection devices or alternatively an approved (P1 or P2) dust mask and safety glasses shall be worn.

It is recommended that work always be carried out in a well-ventilated location.

The most suitable cutting methods are:

• Score and Snap

Score the sheet face 4 or 5 times with a ‘score and snap’ knife. Support the scored edge and snap the sheet upward for a clean break.

• Hand Guillotine

Cut on the off-cut side of the line to allow for the blade thickness.

• Drilling

Use normal high-speed drill bits. Do not use the drill’s hammer function. For small round holes, the use of a hole-saw is recommended.

For small rectangular or circular penetrations, drill a series of small holes around the perimeter of the cut out. Tap out the waste piece from the sheet face while supporting the underside of the opening to avoid damage. Clean rough edges with a rasp.

Large rectangular openings are formed by deeply.

scoring the perimeter of the opening. Next, form a hole in the centre of the opening (refer method above) then saw cut from the hole to the corners of the opening. Snap out the four triangular segments. Clean rough edges with a rasp.

Sheet Layout

Duratex must be joined over a stud and the ends of the sheet to be supported by the top/bottom plate. Butt sheets tightly together except where control joints are employed or at an internal corner.

On internal corners leave a 3~5mm gap for polyurethane sealant. (Refer Figure 5)

At external corners, the sheet joint must finish flush – do not leave any gap. (Refer Figure 6)

Vertical fixing of sheets is recommended. When fixing more than one sheet high, vertical joints must be in line.

Framing studs should be spaced at maximum centres of 600 mm so they will conform to the sheet widths.

Horizontal fixing of Duratex is permissible only where the cladding depth does not exceed the sheet width, ie 1200 mm.

Fixing Instructions

The success of any jointing system is very much dependent upon the correct construction of the framing, the fixing of the Duratex, and the application of the jointing materials.

Duratex sheets must be dry before fixing to the framing structure. Sheet cuts, which are to be flush jointed, must be recessed on site (see Figure 1). The Hitachi ‘Easy Bevel’ (Model EB100) is specifically designed for this purpose.

Figure 1 – Duratex On Site Recessing

Construction Details – Framing

Duratex is suitable for use with both timber and lightweight steel framing.

General

  • Framing must be constructed to comply with the Building Code of Australia.
  • The framing must be set to a true plane to ensure a straight finish to the wall.
  • Studs must be spaced at a maximum of 600 mm centres
  • Noggings must be spaced at a maximum of 1350 mm centres. See Figure 2.
  • Duratex wall sheets must not be joined off the framing.

Timber Framing

Timber framing must comply with AS 1684.2 & .3 1999 Residential Timber – Framed Construction.

Duratex must not be fixed to wet framing. It is strongly recommended that kiln dried timber is used for framing.

If sheets are fixed to ‘wet’ framing problems may occur at a later date due to excessive timber shrinkage.

Metal Framing

Metal framing must comply with AS 3623 – 1993 Domestic Metal Framing.

Duratex may be fixed directly to lightweight metal framing. The metal framing must not exceed 1.6 mm in thickness.

If Duratex is used with rigid steel framing, it must be battened out with either timber or lightweight steel battens prior to fixing.

Timber battens must have a minimum thickness of 40 mm to allow adequate nail penetration. Battens supporting sheet joints must have a minimum actual face width of 45 mm.

Fasteners

For general applications Duratex sheets are fixed to timber framing using 30 x 2.8 mm galvanised flat-head nails.

30 x 2.8 mm Galvanised Flat Head Nail

For fixing Duratex sheets to metal frames, use No. 8 x 20mm galvanised self-embedding head screws.

No.8 x 20 mm Galvanised Self-embedding Head Screw

Sheet Fixing

Duratex sheets are to be installed vertically and fixed at a Sarking maximum of 200 mm centres.

For details on bracing see pages 13 & 14 where fasteners are at 150 mm around the perimeter and 200 mm centres in the body of the sheet.

Do not place fixings closer than 12mm from sheet edges, or closer than 50mm from sheet corners.

The sheet must be held firmly against the framing when fixing to ensure breakout does not occur on the back.

Figure 2 – Sheet Fixing

 Sarking

In wall cladding applications, the installation of a vapour permeable perforated sarking between Duratex and the framing is recommended.

Under windy conditions the building’s internal pressure will generally be less than the external air pressure, this will tend to draw water through flashing and seals if sarking is not used.

Use of a reflective perforated sarking will enhance the insulation properties of the cladding system.

Joint Details

Figure 3 – Joint Details Timber Frame Construction

Figure 4 – Joint Details Steel Frame Construction

Figure 5 – Internal Corner Joint

Figure 6 – External Corner Joint

Control Joint

Where a continuous wall is longer than 4800mm but no longer than 6000mm, a vertical relief joint must be incorporated in this wall structure (see Figure 7).

Where the continuous wall is over 6000mm in length, a full vertical control joint is required at a maximum of 6000mm. The vertical control joint must form a complete break in the structural element, including the top and bottom plates and not just the sheet cladding. Use square cut edges to form these movement joints (see Figure 8).

Relief and control joints require a 6mm gap between sheets and are best incorporated in the structure at window and door opening or behind where a downpipe is to be located.

Figure 7 – Vertical Relief Joint

Figure 8 – Vertical Control Joint

Horizontal Relief Joints

Horizontal Relief Joints must be provided if the wall height exceeds 5400mm or wherever floor joists occur. (This is imperative if non-kiln dried timber floor joists or framing is used).

Alternatives to this relief joint are:

  • To use a horizontal “Z” flashing strip.
  • Let the floor joists overhang the top plates of the lower floor to create a sealed sheet overlap.

Figure 9 – Typical Horizontal Relief Joint

The Architectural profile must overhang the bottom sheet by a minimum of 25 mm.

Horizontal Relief Joints

Duratex must not be applied to nominal horizontal surfaces such as the tops of parapets, sills, decking upstands, etc. These surfaces must be sloped a minimum of 15o to the horizontal for light-texture finishes, or a minimum of 30o for heavy-texture finishes. The alternative is to install a fully sealed and waterproof membrane system immediately under the cladding on the horizontal surface or install a capping.

Wall Abutment

Control Joints must be employed when an addition is constructed onto an existing building or when a masonry wall adjoins a timber or steel framed construction.

Control Joints should be constructed using 9 mm diameter backing rod and polyurethane sealant on abutment to existing masonry walls.

Ground Clearance

Duratex must not be used in situations where it will be below ground or where it will be buried in the ground. The ground clearances as set out in figure 10 must be adhered to at all times.

Figure 10 – Ground Clearance

 

Figure 11 – Typical Window Frame Weather Proofing

Window and Door Openings

To reduce the incidence of cracks appearing in the jointing, flush jointed sheets should be cut in (200 mm minimum) around window and door openings as depicted in Figure 12.

If a sheet joint must coincide with the corner of an opening, BGC Fibre Cement recommend installation of a relief joint to control cracking. See Figure 7.

Figure 12 – Typical Window Frame Weather Proofing

Eaves Detail

Where there is an eave on the building, the Duratex sheet must finish a minimum 6.0 mm short of the eave. The 6.0 mm gap can be filled with polyurethane sealant or a timber moulding can be fitted. Texture coating must not cover the sealant or the timber.

Joint and Coating Systems

Proprietary joint and coating systems for fibre cement sheets have been developed by a number of coating manufacturers. The jointing and coating system must be applied by applicators recommended as suitable by the joint and coating manufacturer.

The selected joint and coating system must be applied to dry, clean sheets only. Application must be completed within 3 months of the sheets being fixed on site, shorterin harsher conditions.

It is strongly recommended that dark colours be avoided as they may cause high temperature variations within the substrate, leading to excessive thermal movement.

Heavier-texture coatings are preferred over smoother finishes, as any minor surface imperfections are less likely to become apparent in critical lighting conditions.

Note: Duratex is not recommended to have a paint finish.

Figure 13 – Typical Joint and Coating Detail

Maintenance

The Duratex cladding system must be maintained to ensure that the system continues to prevent moisture entering the building.

Check flashing, sealant joints and coating systems annually:

  • Flashings must continue to perform their design function.
  • Rake out and replace damaged or cracked sealant.
  • Replace damaged sheets and reinstate coating system as for new work.

Coatings must be maintained in accordance with the coating manufacturer’s instructions.

Fire and Acoustic Rated Walls

Duratex is suitable for external wall applications where fire and acoustic ratings are required in conjunction with BGC Fireboard.

FRL LOAD BEARING  CAPACITY CAVITY INFILL Rw
60/60/60
Branz Test No.
FR 2924
UDL of 9 kN per stud Nil 46+
-/90/90
Branz Test No.
FR 2924
Non loading bearing Nil 46+

FRL LOAD BEARING CAPACITY CAVITY INFILL Rw
90/90/90
Branz Opinion
FAR 1764
UDL of 6 kN per stud R 1.8 Insulation Batts 43+

+ The Rw values are opinions based on tests conducted by Marshall Day Acoustics Pty Ltd.

Bracing

BGC 7.5mm Duratex can be used to provide bracing to resist racking loads due to wind loadings when installed vertically.

Where 7.5mm Duratex is used to provide bracing on timber dwellings, the Australian Standard for “Residential timber-framed construction” must be adhered:

AS1684.2-1999 (Non-cyclonic areas)
AS1684.3-1999 (Cyclonic areas)

Racking forces due to wind loading shall be calculated as per these Australian Standards.

For bracing data on other construction methods and applications, contact your BGC Fibre Cement Sales Office.

Nominal Wall Bracing

Up to 50% of the total bracing requirements can be supplied by BGC 7.5mm Duratex sheeting installed normally. To be eligible for inclusion in calculations as nominal wall bracing:

  • The minimum length of each nominal bracing panel shall be 450mm.
  • Nominal bracing shall be distributed evenly throughout the building.

The Bracing Capacity for nominal bracing is given in the following table.

Nominal Sheet Bracing Walls

METHOD BRACING CAPACITY (KNm)
Sheeted one side only 0.45
Sheeted two sides 0.75

Figure 14 – Duratex Bracing Capacity Using Tie Down Bolts

Fastener Spacing

When using tie down bolts, fasteners are to be fixed at 150 mm max around sheet perimeter and 200 mm max in the body of the sheet.

STUD CENTRE (mm) CLADDING BRACING CAPACITY (k/N/m)ULS*
600 One Face Only 3.6
450 One Face Only 3.75
*Ultimate Limit State design.
These results are from testing on JD5 Grade timber. If hardwood frames (JD2) are used, the ULS will increase by 12.5%.
Permisable Stress Design (PSD) = Ultimate Limit State (ULS)/1.5

Bracing

Figure 15 gives the design bracing capacity for panels secured with anchor rods. This table can be considered to be an addition to Table 8.18, AS1684.2 – 1999/AS1684.3 – 1999.

Figure 15 – Duratex Bracing Capacity Using Anchor Rods

 

Fastener Spacing

When using anchor rods, fasteners are to be fixed at 150 mm max around sheet perimeter and 200 mm max in the body of the sheet.

STUD CENTRE (mm) CLADDING BRACING CAPACITY (k/N/m)ULS*
600 One Face Only 5.1
450 One Face Only 5.3+
*Ultimate Limit State design.
These results are from testing on JD5 Grade timber. If hardwood frames (JD2) are used, the ULS will increase by 12.5%.
Permisable Stress Design (PSD) = Ultimate Limit State (ULS)/1.5+Calculated through interpolation.

Panels Height Greater Than 2700mm

The bracing capabilities, Figure 14 and 15 are applicable to a maximum panel height of 2700mm.

For panel heights greater than 2700mm the bracing capacity shall be reduced using the panel height multipler given in the below table.

Bracing Capacity – Panel Height Multiplier

WALL HEIGHT (mm) MULTIPLIER
3000 0.90
3300 0.80
3600 0.75
3900 0.70
4200 0.64

Panel Length Less Than 900mm

The bracing capabilities, Figures 14 and 15 are applicable to a minimum panel length of 900mm. Effective bracing is achievable with panel lengths down to 450mm. Reduce the bracing capacity for panel between 450mm and 900mm long, using panel length multiplier given in the below table.

Bracing Capacity – Panel Height Multiplier

WALL HEIGHT (mm) MULTIPLIER
850 0.92
800 0.83
750 0.75
700 0.66
650 0.58
600 0.50
550 0.42
500 0.33
450 0.25

Thermal Break Details

Thermal breaks are required for steel framed habitable buildings. Careful consideration of thermal heat transfer and the position of thermal breaks need to be addressed by the architects, engineers and building designers. Thermal breaks should be installed between the lightweight steel CFS stud and or top hat sections and the Duratex cladding. Non-enclosing wall elements may not require thermal bridging, except where the possibility of high thermal heat transfer exists through to the main structural steel element of the building.

Duratex 9.0mm in Commercial Situations

BGC Duratex 9.0mm offers the designer and building owner a masonry look solution, for institutional, commercial and industrial buildings.

Duratex clad walls up to 6m long and 1.2m, 3.0m or 4.2m high, can be constructed using a standard technique flush jointing system, supplied by the same manufacturer of the high build coating system.

For a long trouble free service life of Duratex, BGC Fibre Cement recommends that prior to installation and fixing, all surfaces are sealed with a sealer compatible with the high-build coating system on the front face.

Design

Design, construction and control joints are kept to minimum and coincide with the building articulation and framing layout, and in accordance with the Duratex design consultant’s detailing.

Fascias are generally 1.2m high, with the sheets laid and fixed horizontally, and Fascias and Facades higher than 1.2m are fixed vertically.

BGC Duratex 9.0mm sheets are 1200mm wide x 2400mm and 3000mm long, with two recessed long edges and one short edge, are primed on both faces and all edges and are available ex-stock.

Framing

Framing can be either in timber or lightweight cold-formedsection (CFS) steel Top-Hat sections or C– section studs. 45mm face-width timber and 38mm face-width Cee stud framing is typically used in smaller framed building or infill panels, up to 3.0m high.

For larger facades, up to 4.2m high, 75mm x 35mm x 1.15mm Top-Hat sections, fixed to structural CFS girts, are used.

Top-Hat and stud spacing is set at 600mm maximum for low wind speed areas, up to 1.5kPa wind pressure, and 400mm maximum spacing for high wind pressure areas, up to 2.5kPa; dependent on girt spacing.

Timber and CFS stud framing must have a mid-point row of noggins for frames above 2.4m high, and where the façade exceeds 1.2m high, the sheets are to be set out vertically.

Fixing

BGC Duratex 9.0mm sheets are fixed to the support framing at 200mm maximum centres along the sheet edges and over intermediate supports.

Fixing must be at 12mm minimum from the sheet edges and 75mm minimum from the corners.

Duratex 9mm fixing detail

Sheets fixed to lightweight CFS steel Top Hat and Stud supports are placed over 6mm x 50mm thermal bridging tape, such as Norton V768 or UNISIL 3208, or equivalent.

Countersunk, self embedding winged, self drilling screws 32mm long complying with AS3655 are to be used when fixing to lightweight CFS steel support framing. Sheets are to be pre drilled if winged screws are not used.

Duratex 9mm screw fixed set joint detail

Fixing to timber framing is effected using 40 x 2.8mm galvanized fibre cement nails, driven flush to the sheet surface.

Control Joints

Vertical and horizontal control joints are required where the wall length exceeds 6m long and height exceeds 3m and as required by the building design, articulation and framing layout, in accordance with the design consultants dealing.

Construction and control joints allow for relative movements between the building mainframes, subframes and cladding systems, due to building settlement, thermal movements and other forces. Flexible/slip joints allow for these movements and consist of a sealed joint, bond breaker tape and fixings.

Where CFS Top Hat sections are used, 10mm construction control joints are affected over two separate supporting Top Hats, as shown in the diagram below.

Module slip/control joints over CFS Top Hat framing must have a 10mm gap between each adjacent module of BGC Duratex panels, as shown in the diagram below.

Horizontal joints are similar to the vertical jointing systems, and may be expressed or have architectural details applied.

Where openings occur, such as doors, windows, signage apertures and the like, relief joints should be used to prevent the possibility of system failure due to induced stresses.

These joints are similar to the module slip/control joint, with a nominal 3mm gap between sheets, in line with the openings vertical edge.

Warranty

BGC warrants its products to be free from defects caused by faulty manufacture or materials. If any of its products are so defective the Company will at its option, repair or replace them, supply equivalent replacement products or reimburse the purchase price.

This warranty shall not apply to any loss or consequential loss suffered through or resulting from defects caused by faulty manufacture or materials.

Fittings or accessories supplied by third parties is beyond the control of BGC and as such is not warranted by BGC.

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BGC Fibre Cement Silhouette Exterior Cladding

Silhouette opens a whole new world of possibilities for creating a building’s personality. Silhouette allows architects, developers and builders to select from a range of feature details or even to create their own custom design for external claddings. Attractive and competitively priced, Silhouette offers a fresh approach to cladding options. Silhouette comprises a fibre cement plank and a uPVC feature strip. Together these components clip together to obscure fixing points and to form a seamless cladding appearance of your choice. The Silhouette Exterior Cladding System:

  • better engineered
  • easier and quicker – thinner material to work with; self aligining
  • simple to build with – uses same construction solutions as a standard weatherboard
  • offers a new standard of finish – seamless, bold appearance
  • lighter – ideal for transportables, extensions, general residential and battened out walls
  • economical – no waste in laps; competitive price
  • choice – 3 individual styles to choose from; additional custom design possible

Product Description Silhouette opens a whole new world of possibilities for creating a building’s personality. Silhouette allows architects, developers and builders to select from a range of feature details or even to create their own custom design for external claddings. Attractive and competitively priced, Silhouette offers a fresh approach to cladding options. Silhouette comprises a fibre cement plank and a uPVC feature strip. Together these components clip together to obscure fixing points and to form a seamless cladding appearance of your choice. Engineered for exterior applications. Silhouette is termite resistant, does not rot and requires minimal maintenance. Silhouette is available in a choice of feature strips Classic, Coastal and Urban and in a choice of planks 230 mm wide and 180 mm wide. The system is complemented by a range of trims and accessories to allow correct detailing and to give a professional finish to every job. Product Information Silhouette plank is manufactured from Portland cement, silica, cellulose fibre and water. The planks are cured in a high-pressure steam autoclave to give a durable, dimensionally stable plank. The feature strips are manufactured from uPVC resin for longevity and impact resistance. The fibre cement in Silhouette is manufactured to conform to AS2908.2 and is classified as Type A.Category 3 for external use. Table 1 – Silhouette Sizes and Mass

Width (mm)& Pattern (mm) Thickness (mm) Length(mm) *ApproxWeight (kg)
230 Smooth 7.5 4200 11.8
180 Smooth 7.5 4200 9.2

*At equilibrium moisture content of 7%. Fire Resistance BGC Fibre Cement products have been tested in accordance with Australian Standards AS/NZS 3837 and AS 1530.3 and are deemed a Group 1 material in accordance with the Building Code of Australia (BCA) Volume 1, Specifications A2.4: Fire Hazard Properties. Silhouette planks have the following AS/NZ 1530.3early fire hazard indices.

  • Ignition Index
0
  • Spread of Flame Index
0
  • Heat Evolved Index
0
  • Smoke Developed Index
0 ~ 1

Silhouette fibre cement planks are suitable where non-combustible materials are required in accordance with C1.12 of the Building Code of Australia. Standard Feature Strips Quality Systems BGC Fibre Cement manufactures Silhouette under the rigorous Quality Management System of the International Standard ISO 9002:1994, and is the holder of Licence Agreement number QEC2955/13. Handling and Storage Silhouette must be stacked flat, up off the ground and supported on level bearers. Silhouette must be kept dry, preferably by being stored inside a building. When stored outdoors it must be protected from the weather. Care should be taken to avoid damage to the ends, edges and surfaces. Silhouette must be dry prior to being fixed, or painted. To avoid breakages Silhouette must be carried on edge. Health and Safety BGC Silhouette is manufactured from cellulose fibre, finely ground sand, Portland cement and additives. As manufactured, the product will not release airborne dust, but during drilling, cutting and sanding operations cellulose fibres, silica and calcium silicate dust may be released. Breathing in fine silica dust is hazardous and prolonged exposure (usually over several years) may cause bronchitis, silicosis or cancer. Avoid Dust Inhalation When cutting sheets, work in a well-ventilated area and use the methods recommended in this literature to minimise dust generation. If using power tools wear an approved (P1 or P2) dust mask and safety glasses. These precautions are not necessary when stacking, unloading or handling fibre cement products. For further information or a Material Safety Data Sheet contact the nearest BGC Sales Office. Quantities Ready Reckoner Table 2 is provided to assist in calculating the number of planks required to cover a given wall height. For example, a wall that is 2400 mm high x 6 m long clad in 180 mm Silhouette would require 19planks:

13 Courses x 6 m Wall Length = 19 Planks
4.2 m (Plank Length)

For triangular areas such as Gable ends, halve the quantities derived for a rectangular wall then add 10% to cover off cuts.  Table 2 – Plank Course Ready Reckoner

Wall Height
Courses 180 mm Plank 230 mm Plank
1 180 230
2 365 465
3 550 700
4 735 935
5 920 1170
6 1105 1405
7 1290 1640
8 1475 1875
9 1660 2110
10 1845 2345
11 2030 2580
12 2215 2815
13 2400 3050
14 2585 3285
15 2770 3520
16 2955 3755
To calculate PVC item strips quantities:
PVC clip = No. planks x 2
PVC feature strip = No. planks x 1.5

 Cutting and Drilling Silhouette may be cut to size on site. If using power tools for cutting, drilling or sanding they must be fitted with appropriate dust collection devices or, alternatively an approved (P1 or P2) dust mask, as well as safety glasses, should be worn. It is recommended that work be carried out in a well-ventilated location. The most suitable cutting methods are: Score and Snap Score the sheet face 4 or 5 times with a ‘score and snap’ knife. Support the scored edge and snap the sheet upward for a clean break.  Hand Guillotine Cut on the off-cut side of the line to allow for the blade thickness. Notching Notches can be made by cutting the two sides of the notch. Score along the back edge then snap upwards to remove the notch. Hand Sawing Silhouettes should be supported close to the cut. A fine toothed saw and a quick jabbing action gives best results. Mark cut lines on face side of the plank. Drilling Use normal high-speed drill bits. Do not use the drill’s hammer function. For small round holes, the use of a hole-saw is recommended. For small rectangular or circular penetrations, drill a series of small holes around the perimeter of the cut out. Tap out the waste piece from the plank face while supporting the underside of the opening to avoid damage. Clean rough edges with a rasp. Cutting PVC Hand cut using a fine tooth saw or alternately a sharp ‘stanley’ knife. Support PVC adequately while cutting / trimming. Rough edges can be dressed by lightly rubbing with ‘wet & dry’ paper. Fasteners Silhouette must be fastened at every stud (or batten for vertical installations). Fasteners should be placed immediately below PVC backing clip. Nails must not be driven closer than 50 mm from the plank end. Nails or fasteners can be located 20 mm minimum from the plank end if the fastener hole is predrilled. Timber Framing Do not overdrive nails. Particular care is needed when using nail guns. If variability occurs, the gun should be set to under- drive and the nails tapped home with a hammer. For standard nails Silhouette is fixed to timber framing using 30 x 2.8 mm galvanised flat head nails. Nails should be driven flush with the sheet face. Lightweight Steel Framing Silhouette is fixed to lightweight steel framing using No.8 x 35 mm self-embedding head screws. Screws should be driven flush with the sheet face and must comply with AS 3566; Class 3 corrosion resistance. Coastal Areas The durability of galvanised nails and screws used for external cladding in coastal or similar corrosive environments can be as low as 10 years. For this reason BGC recommend the use of Stainless Steel fasteners within 1 km of the coast or other large expanses of salt water. Construction Details FramingIn general the layouts presented in this publication will be satisfactory for low-rise (up to two storey) domestic and light commercial buildings in non-cyclonic regions. Buildings in cyclonic regions, high-rise buildings, large industrial and commercial complexes will generally require a specific design to be undertaken. The relevant design details pertaining to Silhouette for various wind classifications, are presented in Figure 1. Silhouette is suitable for installation on either timber or lightweight steel framing.

Figure 1 – 7.5 mm Silhouette Wall and Gable End Cladding

Timber Framing Timber framing should comply with AS 1684: Residential Timber-Framed Construction and timber framing must be dry prior to fixing Silhouette. If planks are fixed to ‘wet’ framing, problems may occur at a later date due to excessive timber shrinkage. It is strongly recommended that kiln dried framing is used. Timber Battens Timber battens must have a minimum thickness of 40 mm to allow adequate nail penetration. Lightweight Steel Framing Silhouette may be fixed directly to lightweight steel framing. Lightweight steel framing should comply with AS/NZS 4600:1: Cold-formed steel structures and AS 3623: Domestic metal framing. The steel framing must not exceed 1.6 mm in thickness. When rigid steel framing is used, it must be battened out with either timber or lightweight steel battens prior to fixing the Silhouettes. Steel Battens Lightweight steel battens should have a minimum face width of 38 mm, a minimum 20 mm depth and be 0.55 mmBMT. The maximum spans and nominal spacings of steel batten top hats are provided in Table 3.

Table 3 – Framing Centres 

GeneralFigure 2 depicts the general framing requirements for Silhouette installed horizontally.

Figure 2 – Silhouette Layout Horizontal Fixing

SarkingThe installation of a vapour permeable sarking between Silhouette and the framing is recommended. The building’s internal pressure will generally be less than the external air pressure under windy conditions, which will tend to draw water through the planking, flashing and seals if sarking is not used. Use of a reflective sarking will enhance the insulation properties of the cladding system. In bush-fire prone or fire source features areas a fire-resistant vapour barrier must be used.

Figure 3 – Infill Panel

Installation

  • Calculate the number of planks required using the Plank Course Ready Reckoner as detailed in Table 2, on page 6.
  • Fix all flashings to wall openings and external and internal corners. See figure 10 for corner details where timber stope ends are used.
  • Set a horizontal datum line around the perimeter of the building using a string line or spirit level. Fix guide nails/ screws along this line to act as a stop for the correct placement of the first course of Silhouette.
  • Attach PVC clip to the top of the plank first (with longer leg facing downwards). See Step 1.
  • Commence fixing the bottom course of plank from an external corner by fastening the top edge of the plank immediately below the PVC clip to each stud. Ensure that the plank is level and flush to the corner. Do not nail home the corner fixing at this time.
  • If using preformed aluminium corners, insert these before nailing home the corner fixing. See figure 7 for this detail.
  • Attach a PVC clip on the top of next plank and locate this plank into the clip of the first plank. See Step 2.
  • Repeat this for remaining planks.
  • For fixings between 20 mm50 mm from the end of a plank, pre drill the plank with a 3 mm hole.
  • The feature strip can now be inserted into the clips between each plank. See Step 3.
  • Ensure feature strip is correct way up. Press into clip opening until firmly in place.
  • Ensure feature strip joints are staggered a minimum 600 mm on subsequent planks.

Figure 4 – 3 Steps of Fixing

Figure 5 – Fixing to Timber Stud

Figure 6 – Fixing to Steel Stud

Figure 7 – External Corner Extrusion

Notes: Secure the pre-formed aluminium corner moulding to corner stud prior to installing Silhouette weatherboards. Install Silhouette weatherboard snug into aluminium corner. The plank end nails must not be closer than 20 mm to the plank end. For nails closer than 50 mmto the plank end pre-drill the plank. The sketch depicts an external corner. The method for internal corners is identical except a pre-formed internal corner piece is used.

Figure 8 – Internal Corner Extrusion

Figure 9 – External Corner – Pressed Metal

Figure 10 – Internal Corner – Timber Stop

Penetrations, Openings, Window and Doors

There are numerous varieties of penetrations, opening, and window and door treatments available, and each weatherproofing detail will be dependent on the material, style and manufacturers specifications. Adequate weatherproofing of the opening application must be considered by the building designer, in conjunction with the penetration, window and door manufacturer. The diagrams are a guide only, and the designer should consult with the appropriate manufacturers, for the detail design to ensure adequate weatherproofing. Cutting Around Openings When cutting planks around window or door openings, a 8 mmnominal clearance must be provided at the jamb, head and sill. A plank joint at one end for small openings and both ends of longer openings will make installation easier and eliminate breakages. Flashing and mouldings must be installed as appropriate to prevent ingress of water into the framing.

Figure 11 – Window and Door Openings

Where a plank has been reduced in width, provide a butt joint at one end of the window or door opening. Where openings exceed 1800 mmwidth, provide a jointer above and below the four corners.

Figure 12 – Still and Jamb Detail Timber Frame

Accessories

   
   
 

 Painting Silhouette is pre-primed for ease of painting. Painting should be completed within 60 days of istallation. Consult paint manufacturers for their recommended paint finish for exterior fibre cement applications. We recommend a wet adhesion promoted paint with a minimum of 2 coats and a light reflective value >45%.  Maintenance Silhouette when used in accordance with this literature requires no direct maintenance. To guard against water penetrating the structure and damaging the framework, annual inspections of the cladding system should be carried out. Check flashing, sealant joints and paint work. Flashing and sealants must continue to perform to their design function. Paintwork should be maintained in accordance with the manufacturer’s instructions. Insulation Silhouette cladding will require insulation to be installed in some regions that have thermal loss regulations. Insulation should be installed in accordance with the manufacturer’s instructions. Insulation bats must fit snugly between framing members to minimise heat loss. Freeze Thaw Silhouette subject to freeze / thaw conditions must be painted. Silhouette should not be used in situations where it will be in direct contact with snow or ice for prolonged periods. BGC Fibre Cement As a division of the Buckeridge Group of Companies, the BGC Fibre Cement operation is situated in Perth, Western Australia and forms an integral part of the groups impressive manufacturing complex. The company relentlessly pursues excellence in all its manufacturing processes, which ultimately provides customers with products of superior quality. Through constant dedication to quality, BGC Fibre Cement has established a reputation for both product and service. BGC Silhouette provides exceptional flexibility durability and strength. Warranty BGC warrants its products to be free from defects caused by faulty manufacture or materials. If any of its products are so defective, the Company will at its discretion, repair or replace them, supply equivalent replacement products or reimburse the purchase price. This warranty shall not apply to any loss or consequential loss suffered through or resulting from defects caused by faulty manufacture or materials. Fittings or accessories supplied by third parties are beyond the control of BGC and as such are not warranted by BGC. Find Out More

BGC DURASCAPE BASE SHEETS

DURASCAPE IS A 9MM THICK FIBRE CEMENT BASE SHEET WITH A 5MM WIDE SHIPLAP JOIN GIVING A SUBTLE VERTICAL SHADOW LINE WHILST COVERING LARGE AREAS. DURASCAPE CAN THEN BE FINISHED WITH ROLL-ON TEXTURED PAINT ON SITE CREATING A RENDERED LOOK.

DURASCAPE IS QUICK TO INSTALL AND CAN BE USED IN SINGLE STOREY AND MEDIUM HEIGHT INSTALLATIONS WHERE A LARGE PANEL LOOK IS REQUIRED.

DURASCAPE BASE SHEETS:

  • GIVE A SUBTLE VERTICAL SHADOW LINE.
  • ARE LIGHTWEIGHT AND DURABLE.
  • QUICK TO INSTALL BECAUSE IT ELIMINATES THE NEED FOR TAPED AND FILLED JOINTS.
  • PANELS ARE NOT AFFECTED BY TERMITES, AIR, STEAM, SALT OR SUNLIGHT.

APPLICATIONS

Durascape is a strong and durable base sheet which has a subtle vertical ship lap joint that is suitable for finishing with a textured paint.

Durascape is suitable for low to medium rise buildings and can be used on both timber and steel framed buildings. It is also ideal for renovations and alterations to existing dwellings.

ADVANTAGES

  • Gives a subtle 5mm vertical shadow line.
  • Is lightweight and durable.
  • Quick to install because it eliminates the need for taped and filled joints and vertical set joints.
  • Panels are not affected by termites, air, steam, salt or sunlight.

ENERGY EFFICIENCY CONSIDERATIONS

Energy efficiency requirements have been introduced into the Building Code of Australia (BCA) for both commercial and residential buildings. Thermal heat transfer into and out of the building envelope will effect the running cost of the building and careful consideration of thermal heat transfer needs to be addressed by the architects, engineers and building designers. Thermal bridging through steel framing will diminish the total R-Value; thermal conductance, of the wall. Thermal breaks are required for steel framed buildings and should be installed between the steel frame and the Durascape panels. Thermal break tapes should have a minimum R-Value of 0.2.

PRODUCT INFORMATION

Durascape panels are manufactured from Portland cement, finely ground silica, cellulose fibres and water. Panels are cured in a high-pressure steam autoclave to create a durable, dimensionally stable product.

Durascape panels are manufactured to the Australian / New Zealand Standard AS/NZS 2908.2-2000 Cellulose-Cement Products, Part 2: Flat sheets and Durascape is classified as Type A-Category 2.

FIRE RESISTANCE

BGC Fibre Cement products have been tested in accordance to Australian Standard AS1530.3.

These tests deemed the following Early Fire Hazard Indices:

Ignition Index 0
Spread of Flame Index 0
Heat Evolved Index 0
Smoke Developed Index 0-1

DURABILITY

BGC Durascape physical properties make it a very durable product.

/ Durascape panels are immune to permanent water damage in both short and long-term exposure.
/ Durascape panels will not rot or burn and are unaffected by termites, air, steam, salt and sunlight.
/ Durascape panels are not adversely affected over a temperature range of 0°C to 95°C.

Vapour permeable sarking must be installed in accordance with the AS/NZS 4200.2 – ‘Pliable building membranes and underlays – Installation’ and the sarking manufacturers’ guidelines. The sarking should have the following properties:

/ Vapour barrier – low or medium
/ Water barrier – high

Vapour permeable sarking is used to prevent moisture ingress by acting as a drainage plane whilst enabling water vapour build up from inside the frame to escape.

THERMAL CONDUCTIVITY

Durascape panels have relatively low thermal conductivity:

R-value. At Equilibrium Moisture content the approximate
R-Value of Durascape is;- 0.55 W/m°C.

WEATHER RESISTANCE / FREEZE THAW

Durascape conforms to the Building Code of Australia (BCA) requirements for external wall applications. Durascape facade system has been tested to AS/NZS 4284 Testing of Building Facades.

Durascape subject to freeze/thaw conditions must be painted.

Durascape should not be used in situations where it will be in direct contact with snow or ice for prolonged periods

PANEL SIZES AND MASS

THICKNESS mm MASS KG/M2 WIDTHmm LENGTH mm
2450 3000
9 12.5 900 x x
1200 x x

SHEET TOLERANCES

/ Width +0/-2mm
/ Length +0/-2mm
/ Thickness +10%/-0%
/ Diagonals difference (max) 2mm
/ Edge straightness deviation (max) 1mm

HANDLING AND STORAGE

Durascape must be stacked flat, up off the ground and supported on equally spaced (max 400mm) level gluts. Care should be taken to avoid damage to the ends, edges and surfaces.

Sheets must be kept dry. When stored outdoors it must be protected from the weather. Sheets must be dry prior to fixing, jointing or finishing.

EXTRA CARE MUST BE TAKEN AT THE SHEET EDGES TO PREVENT CRACKING OF THE SHIPLAP JOIN.

COASTAL AREAS

The durability of galvanised nails and screws used for exterior cladding in coastal or similar corrosive environments can be as low as 10 years.

For this reason BGC recommend the use of stainless steel fasteners within 1km of the coast or other large expanses of salt water.

ACCESSORIES AVAILABLE FROM BGC

EPDM FOAM GASKET
(Used to prevent moisture ingress at sheet joins).
25m  
INTERNAL CORNER 3000mm  
EXTERNAL CORNER 3000mm  
HORIZONTAL FLASHING 3000mm  

FASTENER

DURASCAPE TO TIMBER FRAME

2.8 x 30mm Fibre Cement Nail (minimum Class 3 corrosion resistant)

2.8 x 40mm Gun Nail (minimum Class 3 corrosion resistant)

/ Screws should be countersunk 1.5mm and filled with BGC Exterior Finishing Compound or Epoxy sealer such as Megapoxy P1, Hilti CA125 or Hilti CA273 and sanded flush to provide a flat surface for finish coating.

/ Nails must be driven flush to the panel surface.

DURASCAPE TO STEEL FRAME

To Steel – 0.75BMT
No 8 x 30mm Countersunk Self Drilling (minimum Class 3 corrosion resistant)

To Steel – 0.8-1.6BMT
8 x 32mm Wingtek Self Embedding Head Screw (minimum Class 3 corrosion resistant)

CONSTRUCTION DETAILS

FRAMING

Durascape panels can be installed vertically to both timber and lightweight steel frames.

Ensure that the frame is square and work from a central datum line. The frame must be straight and true to provide a flush face to receive the panels.

BGC recommend a maximum tolerance of 3mm-4mm in any 3000mm length of frame.

Durascape will not straighten excessively warped or distorted frames and any warping may still be visible after Durascape is applied. Warped framing will require remedial action.

FRAME STRAIGHTNES

TIMBER FRAMES

Use of a timber frame must be in accordance with AS1684 – Residential timber-framed construction and the framing manufacturers’ specifications.

Use only seasoned timber. Do not use unseasoned timber as it is prone to shrinkage and can cause sheets and frames to move up.

Timber used for house construction must have the level of durability appropriate for the relevant climate and expected service life conditions including exposure to insect attacks or to moisture which could cause decay” – Reference AS 1684.2

The framing width at sheet joints must be a minimum of 45mm. The intermediate support studs should be a minimum width of 35mm.

LIGHTWEIGHT STEEL FRAMES

Use of steel frame must be in accordance with AS3623 – Domestic metal framing and the framing manufacturers’ specifications.

Framing members must have a Base Metal Thickness (BMT) between 0.50 to 1.6mm. The steel framing must have the appropriate level of durability required to prevent corrosion. The framing width at sheet joints must be a minimum of 50mm. The intermediate support studs should be a minimum of 64 x 35mm.

MAXIMUM STUD & FASTENER SPACING

GENERAL AREAS
 OF WALLS (MM)
WITHIN 1200MM OF
 BUILDING EDGES (MM)
Wind  Classification
 AS4005
Stud  spacing
 (mm)
Fastener
 Spacing
Stud
 Spacing
Fastener
 Spacing
N1, N2, N3, N4 600 200 600 200
N5 450 200 300 150
N6 450 150 300 125
C1, C2 600 200 600 200
C3 450 200 300 150
C4 450 150 300 125

INSTALLATION

FASTENER POSITIONING

Durascape panels should be installed vertically with all sheet edges fully supported. The centre joints must coincide with the centre lines of the framing member and all sheets should be installed in one direction.

APPLY EPDM FOAM GASKET

At every vertical joint, fix a continuous strip of EPDM Foam Gasket to the vapour permeable sarking along the stud.

This assists to prevent the ingress of moisture at the sheet joins.

SHEET EDGE POSITION

Position the underlap sheet on every stud 3mm past the centre of the stud to ensure the fasteners fixed at the edge of the sheet have adequate distance into the stud.

As detailed on p6, there are several different fasteners that can be used to fix Durascape panels.

FIBRE CEMENT NAIL FIXING – TIMBER FRAME

FLUSH SCREW – LIGHTWEIGHT STEEL FRAME

COUNTERSUNK SCREW – LIGHTWEIGHT STEEL FRAME

To fix the first sheet, set in place ensuring the required edge distances are maintained.

FIX FIRST SHEET

FIX NEXT SHEET

Once both sheets are fixed, check the joint for gaps and fill with additional sealant if required.

Apply of continuous 4mm bead of sealant to the edge of the shiplap join.

APPLY SEALANT

INSTALLATION DETAILS

The architectural intent and details of buildings vary from one designer to the next, and the variety of facade details would be impossible to catalogue.

The detail diagrams following are intended to assist the designer in achieving a high quality weather resistant Durascape installation.

The designer should not digress from the specification set out in this manual.

SLAB EDGE/EAVE JUNCTION 

EXTERNAL CORNER – SEALANT OPTION

EXTERNAL CORNER – STEEL

INTERNAL CORNER – SEALANT OPTION

INTERNAL CORNER – STEEL

WINDOW HEAD

WINDOW SILL

WINDOW JAMB

VERTICAL BUTT JOINT

LOWER FLOOR JUNCTION

UPPER FLOOR JUNCTION

UPPER FLOOR JUNCTION – OPTION 2

HORIZONTAL JUNCTION 1

HORIZONTAL JUNCTION 2

THERMAL BREAKS

Thermal breaks are required for steel framed buildings, in walls enclosing habitable and or usable spaces. Careful consideration of thermal heat transfer and the position of thermal breaks need to be addressed by the architects, engineers and building designers.

Balustrades, parapets, and other non-enclosing wall elements may not require thermal bridging, except where the possibility of high thermal heat transfer exists throughthe steel CFS sections to the main structural steel element of the building.

MOISTURE MANAGEMENT

Designers, specifiers and builders have a duty of care to identify moisture-associated risks with any individual building design.

Wall construction design should consider both the interior and exterior environments of the building to effectively manage moisture. Special consideration should be given to buildings that are in extreme climates or at higher risk of wind driven rain.

In addition, all wall openings, penetrations, junctions, connections, window heads, sills and jambs must incorporate appropriate flashing for waterproofing. All other components, materials and installation methods used to manage moisture in walls should comply with the relevant standards of the Building Code of Australia (BCA).

WARRANTY

BGC warrants its products to be free from defects caused by faulty manufacture or materials. If any of its products are so defective the company will at its option, repair or replace them, supply equivalent replacement products or reimburse the purchase price.

This warranty shall not apply to any loss or consequential loss suffered through or resulting from defects caused by faulty manufacture or materials.

Fittings or accessories supplied by third parties are beyond the control of BGC and as such is not warranted by BGC.

BUSHFIRE AND BOUNDARY WALL AREAS

BGC Durascape is eminently suited for both bushfire and boundary wall applications in residential and multi residential buildings.

BGC Durascape can be used as a stand alone product to achieve up to BAL 40 when fixed direct to frame as per the fixing instructions in this manual.

BGC Durascape when used in conjunction with BGC 16mm Wet Area Fireboard will comply with the requirements of AS3959:2009 and AS1530.4 to achieve BAL FZ>10 as well as 60 minute and 90 minute boundary wall systems.

BUSHFIRE AS3959:2009 APPLICATIONS

AS3959:2009 sets out a series of Bushfire threat levels to buildings described as BAL (Bushfire Attack Levels) as follows:
BAL-Low, BAL-12.5, BAL-19, BAL-29, BAL-40 or BAL-FZ (Flamezone).

BGC Durascape may be used to achieve a BAL-40 or BAL-FZ>10 when used in conjunction with 16mm Wet Area Fireboard.

BOUNDARY/EXTERIOR WALLS

BGC Durascape in conjunction with BGC 16mm Wet Area Fireboard can achieve both 60/60/60 and 90/90/90 FRL fire ratings from the outside as required by the BCA.

Where an exterior wall is required to achieve 60/60/60 FRL (Fire Resistance Level) from the outside, 1 layer of 16mm BGC Wet Area Fireboard installed with BGC Durascape over the Wet Area Fireboard will meet minimum BCA requirements.

Similarly 2 layers of 16mm BGC Wet Area Fireboard used in conjunction with BGC Durascape will achieve 90/90/90 from the outside.

NOTE: All external walls must have sarking beneath the BGC Durascape No adhesives are to be used when installing Wet Area Fireboard and the BGC DurascapeTM. Nails or screws must be used.

For more information please contact your nearest BGC Fibre Cement office.

BOUNDARY WALL SYSTEM

Find Out More

BGC NULINE WEATHERBOARD

NULINE IS A UNIQUE, WEATHERBOARD-STYLE CLADDING SYSTEM THAT LOOKS LIKE REAL TIMBER WEATHERBOARD, BUT DOESN’T COME WITH ANY OF THE MAINTENANCE ASSOCIATED WITH NATURAL TIMBER WEATHERBOARD CONSTRUCTIONS.

THE NULINE WEATHERBOARD EXTERNAL CLADDING SYSTEM:

  • FEATURES A LEVEL JOINING SYSTEM, WHICH GIVES A SEAMLESS FINISH
  • IS QUICK AND EASY TO CUT, HANDLE AND INSTALL
  • COMES IN TWO DIFFERENT PROFILESOFFERING ‘DESIGN’ CHOICE
  • IS DURABLE
  • WON’T ROT OR DECAY
  • IS LOW MAINTENANCE
  • OFFERS A RANGE OF ATTRACTIVE CORNER AND END FINISHES
  • IS ENVIRONMENTALLY FRIENDLY
  • IS FIRE RESISTANT
  • IS TERMITE RESISTANT
  • ACHIEVES BAL 40 AS REQUIRED IN AS3959:2009 – CONSTRUCTION OF BUILDINGS IN BUSHFIRE PRONE AREAS
  • QUICK AND SIMPLE TO INSTALL USING MANUAL NAILING, GUN NAILING OR SCREW FIXING


 PRODUCT DESCRIPTION

NuLine Weatherboards are a general-purpose fibre cement cladding for external applications. They are manufactured as planks, which are reminiscent of traditional weatherboards both in appearance and installation methods.

NuLine Weatherboards are not subject to timber rot, decay, or white ant damage and will not support combustion. The result is a safer, more durable cladding that requires minimum maintenance.

NuLine is available in a smooth finish. At 14 mm thick, NuLine has the strength to withstand the rigours of all normal family activities.

ADVANTAGES

  • Features a level joining system utilising a biscuit joiner
  • Quick and easy to cut, handle and install
  • Durable and low maintenance
  • Won’t rot or decay
  • Environmentally friendly

 ENERGY EFFICIENCY CONSIDERATIONS

Energy efficiency requirements have been introduced into the Building Code of Australia (BCA) for both commercial and residential buildings. Thermal heat transfer into and out of the building envelope will effect the running cost of the building and careful consideration of thermal heat transfer needs to be addressed by the architects, engineers and building designers. Thermal bridging through steel framing will diminish the total R-Value; thermal conductance, of the wall. Thermal breaks are required for steel framed buildings and should be installed between the Peer top hat sections and the Duracom cladding. Thermal break tapes should have a minimum R-Value of 0.2.

PRODUCT INFORMATION

NuLine Weatherboards are manufactured from Portland cement, finely ground silica, cellulose fibres and water. Planks are cured in a high-pressure steam autoclave to create a durable, dimensionally stable product.

NuLine Weatherboard fibre cement products are manufactured to conform to the requirements of AS2908.2 Cellulose-Cement Products and are classified as Type A Category 3 for external use.

FIRE RESISTANCE

BGC Fibre Cement products have been tested in accordance to Australian Standard AS1530.3 – 1989.

These tests deemed the following Early Fire Hazard Indices:

  • Ignition Index
 0
  • Spread of Flame Index
 0
  • Heat Evolved Index
 0
  • Smoke Developed Index
  0-1

PANEL SIZES AND MASS

Nuline weatherboard panels are available in the following sizes.
THICKNESS
mm
MASS
KG/M2
WIDTH
mm
LENGTH
mm
14 4.13 175 Smooth 4200
4.83 225 Smooth 4200

Sizes available in Square and Bullnose profiles.

PLANK TOLERANCES

  • Width +0/-1 mm
  • Length +0/-2 mm
  • Thickness +10%/-0%
  • Diagonals difference (max) 2 mm
  • Edge straightness deviation (max) 1 mm

PROFILES

HEALTH AND SAFETY

BGC NuLine is manufactured from cellulose fibre, finely ground sand, Portland cement and additives. As manufactured, the product will not release airborne dust, but during drilling, cutting and sanding operations cellulose fibres, silica and calcium silicate dust may be released.

Breathing in fine silica dust is hazardous and prolonged exposure (usually over several years) may cause bronchitis, silicosis or cancer.

AVOID DUST INHALATION

When cutting planks, work in a well-ventilated area and use the methods recommended in this literature to minimise dust generation. If using power tools wear an approved (P1 or P2) dust mask and safety glasses.

These precautions are not necessary when stacking, unloading or handling fibre cement products.

QUANTITIES READY RECKONER

Table 1 is provided to assist in calculating the number of planks required to cover a given wall height.

For triangular areas such as Gable ends, halve the quantities derived for a rectangular wall then add 10% to cover off cuts.

Table 1 Plank Course Ready Reckoner
PLANK
COURSES
WALL HEIGHT
175 mm PLANK
30 mm OVERLAP
205 mm PLANK
30 mm OVERLAP
1 175 205
2 320 380
3 465 555
4 610 730
5 755 905
6 900 1080
7 1045 1255
8 1190 1430
9 1335 1605
10 1480 1780
11 1625 1955
12 1770 2130
13 1915 2305
14 2060 2480
15 2205 2655
16 2350 2830
17 2495 3005
18 2640 3180
19 2785 3355
20 2930 3530

CUTTING AND DRILLING

Nuline planks may be cut to size on site. If using power tools for cutting, drilling or sanding they must be fitted with appropriate
dust collection devices or alternatively an approved (P1 or P2) dust mask and safety glasses shall be worn. It is recommended that work always be carried out in a well-ventilated location.

The most suitable cutting methods are:

/ DURABLADE

180mm Diameter.
This unique cutting blade is ideal for cutting Fibre Cement. Can be fitted to a 185mm circular saw, ie Makita or similar. Please ensure safe working practices when using.

/ NOTCHING
Notches can be made by cutting the two sides of the notch. Score along the back edge then snap upwards to remove the notch.

/ DRILLING
Use normal high-speed masonry drill bits. Do not use the drill’s hammer function. For small round holes, the use of a hole-saw is recommended. For small rectangular or circular penetrations, drill a series of small holes around the perimeter of the cut out. Tap out the waste piece from the sheet face while supporting the underside of the opening to avoid damage. Clean rough edges with a rasp.

Large rectangular openings are formed by deeply scoring the perimeter of the opening. Next, form a hole in the centre of the opening (refer method above) then saw cut from the hole to the corners of the opening. Snap out the four triangular segments. Clean rough edges with a rasp. (see method above) then saw cut from the hole to the corners of the opening. Snap out the four triangular segments. Clean rough edges with a rasp.

HANDLING AND STORAGE

NuLine planks must be stacked flat, up off the ground and supported on equally spaced (max 300mm) level gluts.

Planks must be kept dry. When stored outdoors it must be protected from the weather. Care should be taken to avoid damage to the ends, edges and surfaces. Planks must be dry prior to fixing, jointing or finishing.

COASTAL AREAS

The durability of galvanised nails and screws used for external cladding in coastal or similar corrosive environments can be as low as 10 years.

For this reason BGC recommend the use of stainless steel fasteners within 1km of the coast or other large expanses of salt water.

ACCESSORIES AVAILABLE FROM BGC

INTERNAL ALUMINIUM CORNER 2700mm  
EXTERNAL ALUMINIUM CORNER 2700mm  
INTERNAL OBTUSE ANGLE 2700mm  
EXTERNAL OBTUSE ANGLE 2700mm  
J MOULD 2700mm  
STARTER STRIP 2700mm  
JOINERS Pack of 60  

FASTENER

NuLine must be fastened at every stud (or batten for vertical installations).

Fasteners must not be placed closer than 12 mm from the plank edge.

NULINE TO TIMBER FRAME

No. 65 x 2.8mm galvanised flat head nails

/ For renovation projects where the original cladding is not removed, longer nails (70 x 2.8mm or longer) will be required.
/ Care is needed when using nail guns. If variability occurs the gun should be set to under drive and the nails tapped home with a hammer.

Nails must not be driven closer than 50 mm from the plank end. Nails or fasteners can be located 20 mm minimum from the plank end if the fastener hole is predrilled. Except for straight joints, planks must be fixed a maximum of 100 mm from the plank end.

NULINE TO STEEL FRAME

No. 8 x 40mm galvanised self embedding head screws

/ Screw fasteners should be located 35mm from the plank edge.

CONSTRUCTION DETAILS

FRAMING

In general, the layouts presented in this publication will be satisfactory for low-rise (up to two storey) domestic and light commercial buildings in non-cyclonic regions.

Buildings in cyclonic regions, high-rise buildings, large industrial and commercial complexes will generally require a specific design to be undertaken. The relevant design details pertaining to NuLine for various wind classifications, are presented in Figure 2.

NuLine is suitable for installation on either timber or lightweight steel framing.

FIGURE 2 WALL AND GABLE END CLADDING

TIMBER FRAMING

Timber framing must be dry prior to fixing NuLine. If planks are fixed to ‘wet’ framing, problems may occur at a later date due to excessive timber shrinkage.

It is strongly recommended that kiln dried framing is used.

LIGHT WEIGHT STEEL FRAMING

NuLine may be fixed directly to lightweight steel framing. The steel framing must not exceed 1.6 mm in thickness.

When rigid steel framing is used, it must be battened out with either timber or lightweight steel battens prior to fixing NuLine Weatherboards.

TIMBER BATTENS

Timber battens must have a minimum thickness of 40 mm to allow adequate nail penetration.

STEEL BATTENS

Steel battens are typically 50mm wide on the face x 35mm deep x 0.75mm thick.

FRAMING CENTRES

GENERAL

Figure 3 depicts the general framing requirements for NuLine™ installed horizontally.

SARKING

The installation of a vapour permeable sarking between NuLine™ and the framing is recommended. The building’s internal pressure will generally be less than the external air pressure under windy conditions, which will tend to draw water through the planking, flashing and seals if sarking is not used.

Use of a reflective sarking will enhance the insulation properties of the cladding system (eg. Gladiator Perforated Wall Wrap or Sisalation 499) or equivalent.

INSTALLATION

  • Calculate the number of NuLine™ Weatherboards required using the Plank Course Ready Reckoner as detailed in Table 1, on page 5.
  • Fix all flashings to wall openings and external and internal corners. See figures 8a and 8b for corner details using BGC aluminium angles.
  • Fix a starter strip (timber or a strip of plank) to the bottom plate to ensure the first row of NuLine™ Weatherboards are packed out to the correct angle. This starter strip is to be continuous around the perimeters of the building and to overhang the slab edge by 50mm. See figure 5 for this detail.
  • Set a horizontal datum line around the perimeter of the building using a string line or spirit level. Fix guide nails/screws along this line to act as a stop for the correct placement of the first course of NuLine™ Weatherboards.
  • NuLine is best suited to be joined off the studs using a factory cut biscuit. See figures 3 and 4 for these details.
  • Commence fixing the bottom course of plank from an external corner. Fasten the bottom edge of the plank to each stud through the starter strip. Ensure that the plank is level and flush with the corner. Do not nail home the corner fixing at this time.
  • Fit the plank joiner (biscuit) to the end of the plank and apply a bead of sealant then continue fixing the bottom course.
  • Install extruded aluminium corners, before nailing home the corner fixing. See figure 7 for this detail.
  • The plank must overlap a minimum of 30mm, and before fixing the second row of planks calculate the overlap so a near full width of plank will finish at the top of the building. Using a piece of timber or plank, fabricate a lap gauge to ensure that the plank coverage is uniform.
  • Fixings must not be driven closer than 50mm from the end of the plank. For fixings between 20mm – 50mm from the end, the plank must be predrilled with a 3mm hole.

PLANK OVERLAPS

Planks must overlap the previous course by a minimum of 30 mm. Higher overlaps may be used to improve weather proofing (particularly when sarking is not used) or to match the wall height to the plank width. See Table on page 5.

CUTTING AROUND OPENINGS

When cutting planks around window or door openings, a 5 mm nominal clearance must be provided at the jamb, head and sill.

Plank courses should be set out so that as near to a full plank width as possible remains under a window, or similar openings. See Figure 9.

A plank joint at one end for small openings and both ends of longer openings will make installation easier and eliminate breakages.

Flashing and mouldings must be installed as appropriate to prevent ingress of water into the framing.

PAINTING

To enhance both the appearance and performance of NuLine™, BGC recommend that at least two coats of a 100% acrylic exterior grade paint be applied. The paint manufacturer’s ecommendation on application and maintenance of the paint system should be followed.

Note: BGC recommend the use of a roller or brush application for best results.

MAINTENANCE

NuLine when used in accordance with this literature requires no direct maintenance.

To guard against water penetrating the structure and damaging the framework, annual inspections of the cladding system should be carried out. Check flashing, sealant joints and paint work.

Flashing and sealants must continue to perform their design function.

Damaged planks should be replaced as originally installed. Paintwork should be maintained in accordance with the manufacturer’s instructions.

INSULATION

NuLine cladding will require insulation to be installed in some regions that have thermal loss regulations.

Insulation should be installed in accordance with the manufacturers instructions.

Insulation bats must fit snugly between framing members to minimise heat loss.

FREEZE THAW

NuLine subject to freeze / thaw conditions must be painted.

NuLine should not be used in situations where it will be in direct contact with snow or ice for prolonged periods.

THERMAL BRIDGING

Thermal breaks are required for steel framed buildings, In walls enclosing habitable and or useable spaces. Careful consideration of thermal heat transfer and the position of thermal breaks need to be addressed by the architects, engineers and building designers.

Balustrades, parapets, and other non-enclosing wall elements may not require thermal bridging, except where the possibility of high thermal heat transfer exists through the steel CFS sections to the main structural steel element of the building.

Thermal breaks should be installed between the Nuline weatherboards and the steel framing.

For further information refer to section 3.12.1.4 of the BCA. Thermal bridging is to be no less that R 0.2

WARRANTY

BGC warrants its products to be free from defects caused by faulty manufacture or materials. If any of its products are so defective the Company will at its option, repair or replace them, supply equivalent replacement products or reimburse the purchase price.

This warranty shall not apply to any loss or consequential loss suffered through or resulting from defects caused by faulty manufacture or materials.

Fittings or accessories supplied by third parties is beyond the control of BGC and as such is not warranted by BGC.

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BGC Fibre Cement Material Safety Data Sheet.

In accordance with the National Occupational Health and Safety Commission (NOHSC) criteria, BGC Fibre Cement products are not classified as hazardous materials.

Identification:- 

Product Name: Duraliner / Durasheet / Duratex / Duralattice / Duralux / Duraplank Ultraform / Compressed / Ceramic & Vinyl Underlays / Nuline /Silhouette/ Duragrid/ Durascape/ Duragroove
Other Names: Fibre Cement Sheets
Manufacturer’s Product Code: Duraliner / Durasheet / Duratex / Duralattice / Duralux / Duraplank Ultraform / Compressed / Ceramic & Vinyl Underlays / NuLine /Silhouette/ Duragrid/ Durascape/ Duragroove
UN Number: None allocated
Dangerous Goods Class & Subsidiary Risk: None allocated
Hazchem Code: None allocated
Poisons Schedule Number: None scheduled
Uses: Fibre cement sheets for use on internal / external wall linings and soffits, also ceramic and Vinyl / Cork Underlays

 Physical Description/Properties:-

Appearance: Factory applied green tint on the face of Duraliner and Duralux, bluetint on face of the Duratex, pink tint on face of Duragrid.and a whitetint to the face of 4.5, 6.0, 9.0 and 12mm Compressed while all otherproducts are cement grey finish.
Boiling Point: (oC) Not applicable
Vapour Pressure: Not applicable
Specific Gravity (H2O = 1) Not relevant
Flashpoint: Not applicable
Flammability Limits: Not flammable
Solubility in water: Not relevant
Reactivity (e.g. with air or water): Not reactive
Auto-ignition Temperature (oC):
Odour Threshold: Slight cement odour
Lower Explosion Limit:
Upper Explosion Limit:
Self accelerating Decomposition:

 Ingredients 

Chemical Name: CASNumber: Proportion: Exposure Limits
Cement (Calcium silicate) 66997-15-1 > 30% 10.0 mg/m3measured as inspirable dust
Sand (Crystalline Silica) 14808-60-7 > 50% 0.1 mg/m3measured as inspirable
Paper pulp (Cellulose) 9004-34-6 < 8% 10 mg/m3measured as inspirable dust
Aluminium Trihydroxide(Hydrated Ground Alumina) 21645-51-2 < 5% 10 mg/m3measured as inspirable dust

Health Hazard Information.

The potential health hazards are related to dust generated from these materials during the use of power tools and sanding. Inhaling dust liberated from BGC Fibre cement may aggravate pre-existing respiratory conditions. The intact BGC Fibre cement does not give off dust or fume during installation or when installed. However, cutting, breaking, drilling or sawing the boards may generate dust.

Health Effects:

Acute:

Swallowed:

Unlikely to occur, however may result in symptoms of acute indigestion.

Eye: 

Excessive dust may cause eye irritation.

Skin: 

The dust, particularly in association with heat and sweat, can cause irritation, but it is not absorbed through the skin.

Inhaled:

Inhaled dust may cause nasal, throat and lung irritation, symptomatic through excess mucus and coughing.

Chronic:

Inhaled:

If respirable crystalline silica levels are not controlled, repeated exposure to excessive dusts of fibre cement products could result in the chronic lung disease Silicosis. However, if the practices noted in this MSDS are followed during cutting and sanding, exposure to airborne dusts should be within recommended occupational exposure standards and no long-term effects are expected.

First Aid:

Swallowed:

Give copious amounts of water to drink.

Eye:

Flush thoroughly with flowing water for at least ten minutes. If symptoms persist, seek medical attention.

Skin:

Wash thoroughly with soap and water.

Inhaled: 

Remove to fresh air.

Advice to Doctor: 

Treat symptomatically.

PRECAUTIONS FOR USE 

BGC Fibre Cement has adopted the following maximum exposure limits, corresponding to the limits set out by the CoA, NOHSC; Exposure Standards for Atmospheric Contaminants in the Occupational Environment:-

Exposure Standards: 

Calcium silica: 10 mg/m3time-weighted average (TWA) as inspirable dust
Cellulose: 10 mg/ m3TWA as respirable dust
Crystalline silica (quartz): 0.1 mg/ m3TWA as respirable dust
Aluminium Trihydroxide: 10 mg/m3time-weighted average as inspirable dust

BGC Fibre Cement recommends keeping exposures to dust as low as practicable and work in a well-ventilated space.

Engineering Controls: 

No dust is generated, unless the fibre cement is cut. Keep exposures to dust as low as practicable, preferably below 5 mg/m3 TWA (time-weighted average) of inspirable dust, to prevent respiratory discomfort. Work in the open air or near external openings in the building, for adequate ventilation. Where dust is generated, in confined spaces, local mechanical ventilation should be used, to direct the dust away from the work areas.

Personal protective equipment should be used in confined spaces and where dust levels exceed the maximum levels. Use safe work practices to minimize dust release and exposure. Clean work areas regularly by wet sweeping or vacuuming with a HEPA filtered vacuum.

 Ventilation:

Where safe work practices, adequate engineering and material handling controls are in place, ventilation is not normally required. Use local mechanical ventilation and or dust extraction in confined areas and where dust could escape into the working environment.

Tools and Equipment;- Repair / Maintenance

Vacuum and or wipe down all tools and equipment prior to maintenance and repair work. Avoid compressed air cleaning where possible, and wear eye and respiratory protection, and clothing as listed below.

Personal Protection:

Use personal safety protection at all times.

Skin Protection: 

Avoid direct skin contact with fibre cement products. Wear loose appropriate clothing, such as long sleeved shirts and long trousers, head protection and standard duty leather or equivalent gloves, which comply with Australian Standard AS 2161: Industrial Safety Gloves and Mittens. Wash work clothes regularly and do not shake out dust.

Eye Protection:

Wear dust resistant non-fogging safety goggles or glasses, which comply with Australian and New Zealand Standard AS/NZS 1336: Recommended Practices for Eye Protection.

Respiratory Protection:

Where safe work practices, adequate engineering and material handling controls are in place and used none may be required. However, BGC Fibre Cement suggests that L or M particulate respirator (dust mask), which comply with Australian and New Zealand Standard AS/NZS 1715: Selection, Use and  Maintenance of Respiratory Protective Devices, and Australian and New Zealand Standard AS/NZS 1716: Respiratory Protective Devices when Exposed to Dust), be used at all times.

Personal Hygiene:

Do not smoke whilst handling and working with fibre cement. Wash dust from skin with mild soap and water after working with fibre cement.

Flammability:

Fibre cement products are non-combustible and non-flammable.

SAFE HANDLING INFORMATION

Storage and Transport: 

Fibre cement sheets should be stored flat and level in a covered dry area. Lift, handle and carry fibre cement sheets on edge. All lifting should be done with a straight back and bent knees. No other special transport requirements are necessary.

Spills and disposal: 

Use wet sweeping and/or vacuuming to clean up dust and waste. Bagged waste should be placed in containers and disposed of with other construction waste in accordance with local authority guidelines.

Fire/explosion hazard: 

Smoking and Other Dust: 

Smoking and inhalation of airborne particulates from other sources may increase the risk of lung disease. Work areas and storage areas should be deemed smoke-free zones.

BGC Fibre Cement, Material Safety Data Sheet (MSDS) is issued in accordance with the CoA, NOHSC Guidelines and any information contained herein must not be altered, deleted or amended.

BGC Fibre Cement reserves the right to amend, publish and issue a new MSDS for any changes in NOHSC Guidelines and Regulations, product materials and / or specifications.

BGC Fibre Cement Pty Ltd accepts no responsibility, expressed or implied, for any changes made to this MSDS document, without written approval by any third party.

At the issue date, the information in the BGC Fibre Cement MSDS sheet is deemed accurate and reliable.

However, BGC Fibre Cement Pty Ltd accepts no responsibility expressed or implied, for any errors and or omissions.

The onus of determining the suitability of the information in the BGC Fibre Cement MSDS documents, in relation any particular purpose and or any specific circumstance rests with the user.

BGC Fibre Cement advises the user should seek guidance, if any uncertainty arises from the information, meaning and or interpretation of the BGC Fibre Cement MSDS sheets.

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Introduction

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.

Fig 1.1 Isometric Concept House

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Benefits

The many benefits of using Hebel PowerBlocks include:

Solid and strong: Hebel PowerBlocks are made from Autoclaved Aerated Concrete (AAC), a strong, solid masonry building material with the advantage of being 25% the weight of conventional concrete.

Acoustic Performance: Significantly reduced sound transmission from room-to-room.

Thermal Resistance: Unique thermal properties result in a more stable inside temperature, reducing the energy required to heat and cool your home, thereby reducing energy bills.

Environmentally friendly: 73% less embodied energy and 61% less greenhouse gas emissions than comparative masonry products*.
*Source: LCA Report GECA 2006

Fire Protection: Non-combustible blocks with frameless construction deliver superior fire resistance. Hebel PowerBlock systems also allow you to build right up to your boundary line.

Pest resistance: Not a food source for termites or vermin and no cavity construction eliminates the chance of harbouring pests.

Design Freedom: Hebel PowerBlock Wall Systems provide absolute freedom to design and build your ultimate dream home – without compromise.

Technical Support: Competent technical support through Hebel distributors.

Energy Efficiency

The unique combination of thermal resistance and thermal mass make building with Hebel a smart choice for meeting Australia’s stringent building regulations.

The thermal performance of a building depends on a number of factors such as orientation and size and aspect of windows. The R-Value of walls and floors can significantly affect the energy-rating outcome of dwellings. A 250mm Hebel PowerBlock has 3 times the R-Value of a cavity brick wall (BCA Vol. 2 Figure 3.12.1.3). The use of Hebel in walls and floors will provide increased thermal performance that can allow more flexibility with other design aspects of a building.

The thermal efficiency of Hebel systems will also reduce the reliance on heating and cooling appliances. The combined effects of running a heater less in winter and fans or air conditioning less in summer can have a big impact on energy costs and the environment.

Single Skin Construction

The AAC masonry constructed from Hebel PowerBlock products is called “Plain Masonry” and the blocks are masonry units referred to as a “Solid Unit”. The type of solid unit is “Autoclaved aerated concrete masonry unit” complying with AS/NZS 4455 – Masonry Units and Segment Pavers.

The larger face dimension and being a single skin, Hebel PowerBlock walls are erected quickly when compared to double brick construction.

Image 2.1:  Hebel PowerBlock home

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Hebel Energy Efficiency, Fire and Acoustic

Table 3.1 shows a number of different external wall configurations and identifies which satisfy the BCA requirement for Climate Zones 1 to 8. Table 3.2 lists the component R-Values used as a basis for Table 3.1. For more information on Hebel and energy efficiency refer to Section 3 and Appendix C and D of the Hebel Technical Manual.

Table 3.1:  BCA Energy Efficiency Compliance

Wall Configuration Satisfies BCA Requirements      
Climate Zone: 1* 2* 3* 4 5 6 7 8
Class 1 & Class 10a Minimum R-Value: 1.4 1.4 1.4 2.2 1.9 2.2 2.4 3.3
1. 250mm Block Only Y Y Y N Y N N N
2. 250mm Block + 25mm Cavity Y Y Y Y Y Y N N
3. 250mm Block + 25mm Cavity + Sarking Y Y Y Y Y Y Y N
4. 250mm Block + 25mm Cavity + 75mm PowerPanel Y Y Y Y Y Y Y N
5. 250mm Block + 40mm Cavity + R1.0 Insulation Y Y Y Y Y Y Y N
6. 250mm Block + 25mm Cavity + Double Sided RFL + 25mm Cavity Y Y Y Y Y Y Y Y
7. 250mm Block + 90mm Cavity + R2.0 Insulation Y Y Y Y Y Y Y Y

*Note: For elevated ground floor slabs an R-Value of 1.9 is required.

Table 3.2:  Wall Element R-Value

System Number Construction Overall Thickness R-Value Rw Rw
 + Ctr
401 8mm Render in Texture Coat and Paint 250mm Hebel PowerBlock10mm Gyprock 268mm 2.1 48 43
402 8mm Render in Texture Coat and Paint 250mm Hebel PowerBlock 28mm furring channels @600mm centres 10mm Gyprock 296mm 2.3 51 43
403 8mm Render in Texture Coat and Paint 250mm Hebel PowerBlock 28mm furring channels @600mm centres Non reflective (normal sarking) 10mm Gyprock 296mm 2.3 51 43
404 8mm Render in Texture Coat and Paint 250mm Hebel PowerBlock 28mm furring channels @600mm centres Reflective foil 10mm Gyprock 296mm 2.6 51 43
405 8mm Render in Texture Coat and Paint 250mm Hebel PowerBlock 28mm furring channels @600mm centres with 50mm 11kg – Bradford Glasswool Non reflective (sarking) 10mm Gyprock 296mm 3.1 53 44
406 8mm Render in Texture Coat and Paint 250mm Hebel PowerBlock 8mm Render in Texture Coat and Paint 216mm 2.1 48 43

Fire

Hebel AAC has a BCA Group Number 1. Hebel PowerBlock walls satisfy BCA2008 Vol.2 Clause 3.7.1.5 (a) (iii) masonry construction and therefore suitable for boundary wall construction on a Class 1 building.

Acoustic

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
200 45 42

Values for PowerBlock only, no linings.

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