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Fire Rated Walls

QT EcoSeries Finishing & Product Information

Posted on July 3, 2011

Services

Ensure service pipes and wires are fixed or checked into the frame and not laid loose in the extended wall cavity. All materials that are susceptible to deterioration due to plasticiser migration must be protected (check with product manufacturer). Some PVC products or electrical cabling that penetrate the coating system and QT EcoSeries Wall Panel, require a conduit to ensure it is protected.Copper pipes require a sleeve, conduit or tape to prevent contact with the wall panel.

Penetrations

Voids or gaps created by service penetrations through the exterior wall require weatherproofing and or waterproofing.  A common method is to inject with expandable polyurethane foam and seal with a long lasting exterior gap sealant to make a weather tight seal. Where practical add a flange or decorative feature over the hole or penetration.

Sealants

Use an exterior grade weatherproof sealant for exterior wall construction and as a general-purpose gap filling. Apply sealant in accordance to manufacturers recommendations. For a sealant to work effectively, the sealant must be applied as shown in the sketch below,Opening Width (D) x Depth (D/2) half the width.  Use backing rodas required.  Ensure surfaces are in good condition clean and free from oil, dust, loose materials including old sealant and release agents.Apply masking tape to surfaces where contact with sealant is not required. Tape should be removed before sealant cures.  Smooth the surface of the sealant and ensure excess sealant is removed. Refer manufacturers curing or drying times before painting.

Heavy & Frequently Adjusted Fixtures:

Heavy items are not to be fitted directly to the QT EcoSeries Wall Panel. They should have their own stand-alone supports or be tied to the supporting wall frame (eg. Clothes lines).  Items subject to frequent handling (e.g. Flood-Lights and sensors) require a mounting plate, to be fixed across at least two or more frame studs to give long term fixing support.  The backing plate must be of a material that will offer, long-term weatherproof durability. If the internal lining is already installed, the mounting plate can be installed externally prior to the installation of the QT EcoSeries Wall Panel.

Product Information

Storage and Handling

Care should be exercised in handling the QT EcoSeries Wall Panels to avoid any damage to edges, ends and faces. Panels must be stacked flat, off the ground and supported on a level platform. Plastic Shrink wrap applied to pallets of panels for transportation from the factory,must be removed at the destination (i.e. distributors warehouse or direct to site) to allow panel to continue drying and equalise with local humidity. The panels must be kept dry at all times by storing under cover, or providing weatherproof covers to the stack. Panels must be dry prior to fixing. Intermittent weather exposure is not detrimental to the panel. However if QT EcoSeries Wall Panels become wet, allow thorough drying before fixing. Drying shrinkage may occur if the QT EcoSeries Wall Panels are not allowed to dry sufficiently. The proprietary Coating System must be applied and completed within 1 month from the date of installation of the QT EcoSeries Wall Panels.

QT EcoSeries Wall Panels and cement based renders, will release their salts and/or fines if saturated; this condition is know as efflorescence. In order to prevent efflorescence the cement products must be sealed to prevent the ingress of moisture and/or installed with careful attention to the weather-tightness details to prevent the ingress of wind driven rain, gutter overflow or moisture tracking along a surface with capillary action. The water that has permeated through the panel and render will collect and dissolve any salts and/or fines that are then released through hairline cracking in the render which are caused by hydro static pressure build up. The dissolved salts and/or fines will crystallise on the external surface. Should efflorescence occur, it is essential that the moisture source be eliminated and any hairline cracking repaired to maintain weather tightness. Refer to coating manufacturer for suitable surface repair techniques.

Panels must always be carried on edge. Any minor damage should be repaired with joint compounds or polyurethane foam. Fixings and other accessories must be stored so that they are kept clean, dry and undamaged. All components must be used within the designated shelf life. Any damage to Clips and Channel may affect the integrity or performance of the wall system. Panel may be cut with an electric circular saw 60 pt tungsten tip blade, diamond blade or handsaw.Panels are best shaped with the use of an electric plane or a hand rasping tool. Holes or services may be formed with the use of an electric fretsaw or drill. When power tools are used for cutting,grinding or forming holes in the panels, appropriate safety measures as set out under the heading of Health and Safety must be observed.All materials that are susceptible to deterioration due to plastics migration or alkalinity of cement base products must be protected.

Quality Policy

QT Systems Pty Ltd is dedicated to delivering quality building systems for internal and external use on residential and commercial projects.  QT Systems Pty Ltd is committed to ensuring that its Conpolcrete building products provide the highest standards and consistency by meeting the requirements of customers and regulatory authorities. This objective is met through the implementation of a Quality System, based upon the requirements of an internationally recognised quality standard: AS/NZS ISO 9001:2000. Continued testing and independent scrutiny will ensure QT Systems Pty Ltd continues to offer an eco-friendly alternative construction material that consistently provides outstanding performance.

Maintenance

Annual inspection of the exterior walls must be made to ensure theyremain in a weatherproof condition. Checks must be made of theexterior coating system, sealants, flashings, control joints and anywater-proofing systems. Should any repairs be required, seek remedialadvice from the manufacturer. If the project is still under the statutorywarranty period contact the appropriate body, or check with yourinsurer.

Limitations of the QT®EcoSeriesWall Panel System

QT®EcoSeries Wall Panels are not designed to provide bracing forthe building. The internal linings or other specifically designed systems must provide external wall bracing.QT®EcoSeries Wall Panels are not suitable to be used for chimneys and flues.QT®EcoSeries Wall Panels must not come in contact with the ground for extended periods of time. The panel must not be used for retaining.This Technical Manual is limited to residential construction, for other applications contact your QT Distributor.Designers must check that the details in this Technical Manual meet their own specific design requirements. For use outside the scope of this Technical Manual, specific design may be necessary. The Architect, Designer, Engineer, Specifier and Builder, are responsible for specificdesign and should ensure compliance with the BCA.

Product Support

Installers are registered trades people, equipped to install the panel and its complementary accessories. These installers, acting as independent contractors, should be industry licensed trades people such as carpenters or dry wall installers who are familiar with the QT EcoSeries Wall Panel system and components. The authorized agent or appointed licensee shall supply all QT EcoSeries Wall Panel system components directly to the contracting or sub-contracting party. We recommend you seek advice from all manufacturers or suppliers, regarding correct installation and maintenance requirements associated with their products. Failure to comply with specification requirements, which may compromise the exterior coating, sealants, flashing, weather proofing and water proofing, will render any manufacturers warranty void.QT Systems Pty Ltd regularly updates its literature to keep up with system and product developments, changing trends in design, and therefore reserves the right, to revise and change its technical information without notice.

Health and Safety

As with all cement based composite products, they contain crystal line silica. Breathing in fine silica dust is hazardous and may result in bronchitis, silicosis (lung fibrosis) and lung cancer. Do not breathe dust, always contain dust during clean up and disposal i.e. place dust in a sealed bag. Safe working practice is to avoid contact with skin,eyes and lungs, e.g. full-length clothing including boots, P1 or P2 dust mask, and safety goggles to AS 1337. (Wash worn clothing regularly, each day). We recommend that you always seek advice for recommended handling, health and safety requirements for products or components by other suppliers and manufacturers. Consult your local Work Place Health and Safety Officer for specific advice. Also see Material Safety Data Sheets for specific products.

General Warranty

New Product 15 year Warranty.This warranty cover limits any cost or liability arising from the supply of defective Conpolcrete products, excluding third party manufactured accessories and components. Liability is limited to replacement and or repair of any defect solely attributable to defective Conpolcrete manufactured products that do not meet the manufacturers standards. No liability is assumed or implied for project supervision or defects caused by improper installation of the system.

Disclaimer

QT Systems Pty Ltd provides the information in this manual in good faith and to the best of its knowledge the information is correct and covers most situations where its products may be used.  However, it is acknowledged that not every possible application of QT products could be covered within this manual therefore specific design and detailing, must be under taken by the designer. The Specifier, Architect, Designer and Engineer for the project are responsible to ensure that the information and details in this manual are suitable for any intended application or specific design.

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QT EcoSeries Coating Systems & Fire Rated Construction Details

Posted on July 3, 2011

Coating /Rendering

The proprietary coating systems consist of polymer-modified cement renders, which must be finished with an acrylic texture and paint. The proprietary coating manufacturer’s instructions and application requirements must be followed at all times. *(Available to download from the QT website)In most cases these coating systems must be applied by an approved applicator. High profile or heavy texture finishes can minimise surface imperfections or glancing light concerns. Light coloured coatings are recommended. Polymer-modified cement renders must not be applied over sealants or control joints.

Pre - Coating System Inspection

Check all internal and external corners are formed correctly and have good straight lines. Check the first horizontal course, and panels above roof lines have a good clean bottom line. Check weep holes have been installed in the first horizontal course. With a 1.8m spirit level check for variations greater than 3mm in the QT EcoSeries Wall Panels, especially where panels butt together.  If variations are found, take the appropriate remedial action eg. rasp to an acceptable level, or re-fix the offending panels.  It is important to eliminate large variations, as they may appear under critical or glancing light conditions. If the internal lining has not yet been installed, advise the building supervisor that internal wall lining cannot be installed using nails as the knocking vibrations will transfer through the frame and crack the render coatings (hairline cracking). Hence internal lining must be screwed. After the inspection has been completed, application of the base coat can begin.

Application of a Polymer Modified Render Base Coat

Trowel an even coat of polymer-modified cement render over the entire QT EcoSeries Wall Panel, embed QT Full Mesh into the wet Render, overlapping  joints by 100mm minimum.  Allow to firm and then screed and or float to a flat and level finish. The purpose of this coat is to even out the substrate and the porosity of the QT EcoSeries Wall Panel. 150mm wide x 300mm long strips of QT 45° Mesh are also required to be set into the base coat at 45° angle across the corner of all windows and door openings into wet render. Do not render or texture over control joints. The above is a generic guide only. Refer to the proprietary coating manufacturer’s instructions fora detailed description of application. Any proprietary coating system specified must meet or exceed the performance criteria of the BCA.

Fire Rated Construction Details

Note: Prior to any firewalls being constructed it is essential that the builder consults with the project certifier to ensure that the certifier is aware of the firewall construction procedures and the certifier deems the installer competent.

FRL - 90 Mins. & External Fire Source

CSIRO Full-Scale Fire Test FS 3685/2695 has proven that the QT EcoSeries Wall System (shown right) is capable of achieving afire resistance of 113 minutes Integrity and 115 minutes Insulation when tested in accordance with AS1530.4. Therefore for the purpose of Building Regulations in Australia, the QT EcoSeries Wall System achieved a fire resistance level (FRL) of 90/90/90.  The FRL is applicable for exposure to fire source from the tested side

(QT EcoSeries Wall Panel side).

FRL - 90 Minutes

To achieve a 90 minute Fire Rating the wall must be constructed so as the wall consists of two layers of 13mm thick fire resistance plasterboard affixed to the timber frame internally and one layer of fire resistant building foil, one layer of 50mm QT EcoSeries Wall Panel with a 5-8mm render applied with finish, affixed directly to a20-50mm battened out cavity. This system would be capable of achieving Fire Resistance Levels of -/90/90 for Non Load Bearing walls and 90/90/90 for Load Bearing Walls designed in accordance with AS1684 for fire exposure from either direction if tested in accordance with AS1530.4

Extended Wall Areas

The Fire Resistance Levels of 60 & 90 minutes would still apply to the same system extended in height in modular form provided that the structural members are designed in accordance with the relevant structural design code for the height and load of actual installation and an approved joint system appropriate to the FRL and the width of the gap is used for the horizontal and vertical joints in a manner's detailed in the attached drawings.

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QT EcoSeries Construction Details

Posted on July 3, 2011

Slab & Floor

All foundations must comply with the relevant standards and local authority requirements, with appropriate consideration given to soil type. QT EcoSeries Wall Panel is suitable for construction on concrete slab or suspended floors.  The concrete slab can either be rebated or non-rebated.  The slab rebate will need to be a minimum of 50mm below floor level and 100mm above paved level or 150mm above ground level (See local standards). To ensure a flush finish, the width of the slab rebate needs to allow for the thickness of the coating system, the thickness of the panel (40mm or 50mm), and the size of the extended wall cavity 20 – 50mm (30mm nom). Minimum ground clearances, must be maintained at all times during the life of the building. Insufficient clearance from the ground to the bottom of the wall panels will affect long-term durability.

Termites

The Building Code of Australia in conjunction with AS 3660 specifies the requirement for termite risk management. (See local standards).

The edge of a slab-on-ground may be used as a visual perimeter barrier. Provided that the slab edge is left exposed not less than 75mm above finished ground or paved level. The face of the perimeter must not be concealed by a flashing, rendered, tiled or clad.

The exposed edge of the slab must be kept clean and free of debris and regularly visually inspected for termite activity. QT EcoSeries Wall Panel does not hold any nutritional value for ants or rodents.

Windows

Wherever possible windows and associated flashings should be installed prior to the installation of the QT EcoSeries Wall Panel.

When ordering the window frame it is essential to plan where the window flange will be positioned either flush with the stud frame, flush with battens or even over the panel.

All materials that are susceptible to deterioration due to plastics migration or alkalinity of cement base products must be protected.

Decorative Mouldings

To provide added design flexibility, decorative mouldings or feature scan be made using QT EcoSeries Wall Panels. The panel can be cut into bands or laminate multiple layers and shape to achieve the desired profile. Once installed, a coating system would then be applied. Alternatively, a wide range of decorative mouldings are available from various manufacturers.

QT EcoSeries Wall Panels can be cut into bands that can be installed around windows, doors, along horizontal control joints, etc to enrich the aesthetics of the project. They are installed so the top and bottom edge (bevelled at 15 degrees) falls away from the wall. Where bands meet, they should be cut at a 45˚ angle, across the face of the corbel to help conceal the join and increase the adhered surface bond.

Bands are bonded into place with polyurethane foam and corbel screws or nails to mechanically fix the bands until the foam is set.

Doors

Door framing must be fixed in position prior to the installation of the QT EcoSeries Wall Panels. The door framing will allow the panel to be cut and installed neat but independent of the frame. Door frames must be fixed to the structural framing. Decorative moulding scan be used to emphasize the door opening.

All materials that are susceptible to deterioration due to plastics migration or alkalinity of cement base products must be protected.

Wall to Roof

Wall to roof details can often be unsightly as they are easily seen and hard to conceal without compromising the weather tightness of the dwelling. Because of its visibility, it is essential to create clean straight lines either by using a uPVC moulding or cover flashings.

Soffit & Eaves

The eaves or roof overhang play a significant role in the comfort performance of the building. Eaves or overhangs are used to shade the walls from the summer sun, while capturing the sun’s heat in the winter. Eaves will reduce glancing light, which highlights the wall surface. Glancing light is the light that is nearly parallel to the surface of the wall and casts visible shadows and uneven projections of the surface finish QT EcoSeries Wall Panels can be installed to suit various soffit designs and details.

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QT EcoSeries Installation and Fixing & Corners, Joints & Junctions

Posted on July 3, 2011

Panel fixings

Fix the QT EcoSeries Wall Panel onto timber battens or metal channels with galvanised 75mm x 3.15 or 3.75mm ring shank nails (timber battens only) or 10g x 75mm Class 3 (AS3566) screws(timber or steel battens) with the addition of QT Buttons in all cases. Panel fixings must be no closer than 50mm but no further than 112mm to the horizontal panel edge and no closer than 50mm to the vertical edge, while normal fixing centres are at 225mm maximum centres. It is essential that the vertical and horizontal butt joints be bonded with polyurethane foam adhesive. Also ensure polyurethane foam adhesive is applied to all batten faces prior to the panel being pushed against them for maximum bonding to the support frame. Panels can be joined off stud, if glued to the abutting panel with polyurethane foam adhesive. QT EcoSeries Wall Panels can span 225mm as an unsupported cantilever.  Panels must span across a minimum of two channels or battens and must be installed in a horizontal stretcher bond pattern. To prevent corrosion from salt aerosols in high corrosion zones, (such as geothermal activity or within a 500m distance from the sea) upgrade fixing screws to class 4 or stainless steel (AS3566).

Framing

Timber framing must comply with AS 1684 and steel framing must be designed and constructed in accordance with AS 3623. Minimum distances from end and edge of timber framing members must be observed to avoid splitting. Stud spacing must not exceed 600mm centres. Noggings must be fitted between studs at 1350mm maximum centres.With a 1.8 m spirit level, check for variations in the frame that are over 6 mm. Large variations negatively affect weather protection or can appear as visual defects under critical light conditions. If therame is out of plumb, but not structurally defective, consult with the builder or contractor for remediation.

Corners, Joints & Junctions

Internal & External Corners

Internal corners can be formed by continuing the QT Full Mesh around the corner or by embedding a QT Corner Mesh into the base coat render. External corners can be formed by embedding a QT Corner Mesh into the base coat render or by fixing a corner bead prior to rendering.In all cases the abutting corner panels must be bonded with polyurethane foam adhesive.

Relief Joints

Relief joints are required to accommodate any structural movement or panel movement due to temperature or moisture changes. If the panel above or below an opening is less than 300mm in depth or more than 2400mm in length the panel must be articulated by creating a vertical expansion joint to reduce and/or relieve the stress in the panel and coating system. All other corner openings must be reinforced with QT 45˚Mesh.

The QT 45˚Mesh helps prevent any 45˚hairline cracks forming from the corner of any opening.

Control joints

Control joints are designed to relieve structural movement between the wall cladding and building frame and also relieve any stress that build sup in the applied coating system. Vertical control joints are required at no greater than 5 metre centres (+ or - 500mm) in walls greater than 8metres in length. Double studs are required at all vertical control joints. Vertical joints are best aligned with windows, doors, openings, or internal corners. Where timber floor joists are used a 15mm (nom), horizontal control joint must be provided at floor levels to allow for shrinkage and movement of the joists. 10mm control joints must also occur where the QT EcoSeries Wall Panels meet alternative wall claddings eg.Weatherboard, brickwork, etc. On gable ends, a horizontal control joint will be required at the top plate of the wall so as to separate the gable wall from the wall below. Control joints can be formed with the use of a backing rod and sealant or by the installation of uPVC expansion bead.

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About QT EcoSeries

Posted on July 3, 2011

This technical manual covers the QT EcoSeries Wall Panel, a masonry veneer wall cladding system with a cavity. The QT EcoSeries Wall Panel is a masonry panel that offers a solid substrate, can provide a wide range of finishes, has high thermal insulation and sound abatement, fire resistance and ease of construction. QT EcoSeries Wall Panels are manufactured from a material called ‘Conpolcrete’ which consists of a blend of cement and recycled polystyrene.

Thermal Performance

The Thermal performance of the QT EcoSeries Wall System is calculated in accordance with AS 2627.1 Thermal Insulation of Dwellings. QT EcoSeries Wall Panel has a k-value of  0.07 w/mk.

Impact Resistance

QT EcoSeries Wall Panel when coated with a cement base render, can provide resistance for hard body impacts typically found undernormal situations.

Acoustic Performance

The QT EcoSeries Wall System was tested in accordance withAS/NZS 1276.1 for Airborne Sound Transmission and achieved STC41 and Rw41(-3;-8)(Wall Composition: 50mm QT EcoSeries Wall Panel with 30mm (nom) cavity on a 70mm x 35mm stud frame and 10mm plasterboard) CSIRO TL399. Acoustic performance can be significantly increased with the addition of bulk or acoustic insulation batts.

fire Performance

QT EcoSeries Wall Panels when tested to AS/NZS 3837 and in accordance with BCA Specification C1.10a Section is classed as a GROUP 1 material.

Durability

In normal conditions and when maintained properly in a weatherproof condition, the cladding systems should exceed 30 years of trouble free serviceable life. When the system is installed in high corrosion zones, such as coastal locations within distances of up to 500m from the sea, particular care must be taken to ensure that openings through the cladding panels are kept to a minimum to prevent corrosive salt aerosols from entering the wall cavity and affecting metal components.

(Permitted openings are base weep holes, soffit vents and openings beneath window joinery at sills).

Wildlife Attack

The panels will not support growth of micro-organisms such as fungi or bacteria and do not hold any nutritional value for ants or rodents.

Cavity

Cavities form an important role in the weather tightness and life cycle of any wall system QT EcoSeries Wall Panels constructed without a cavity will void any warranty. The cavity acts as a secondary barrier against wind driven rain penetration entering the wall framing. The cavity also allows the wall to ventilate and drain which is essential for a healthy wall.

Vapour Permeable Sarking

Vapour permeable sarking must be installed to the face of the building framing prior to installation of the battens and panels. The vapour permeable sarking has two main functions, weather tightness and thermal resistance. In its weather tightness role it protects the building framing from direct contact with moisture generated by wind driven rain penetration, while allowing the condensation of moisture from interior artificial heating and cooling to escape. Thermally the vapour permeable sarking divides the wall into two separate air spaces, which significantly increases the thermal performance of the wall.1.

Weepholes

On the first horizontal course (ground level) weep holes are to be installed at centres not exceeding 1200mm immediately above any damp proof membrane or flashing. Weep holes are also require din areas where there is a possibility of moisture build up. Weep holes must be limited to 8mm in width to reduce the potential for vermin access.

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