FIRE RATED INSULATED WEATHERTIGHT GREEN I WALLS CEILINGS ROOFS I COMMERCIAL INDUSTRIAL ARCHITECTURAL RESIDENTIAL FEATURES UTILISATION APPLICATION 0800 430 430 Email info@bondor.co.nz Website www.bondor.co.nz Structural Insulated Panel Guide 2011 Bondor New Zealand Ltd is a nationally established manufacturer of structural insulated panels, re rated insulation materials and expanded polystyrene (EPS) construction products. With over 40 years of trading experience in manufacturing and construction we are recognised as the market leader in our industry we take pride that our name is associated with integrity and professionalism. With manufacturing sites in Auckland and Christchurch and branches in Dunedin and the Bay of Plenty, we provide an integrated approach to the construction and supply of our products. Our construction teams travel throughout New Zealand, providing professional and reliable advice to all our clients; and we like to do things to specication, on time and in full. Our services include: Bondor New Zealand also offers and supplies a warranted installation service as well as a complete range of ashings, aluminium extrusions, insulated doors and construction components. INTRODUCTION TO BONDOR NEW ZEALAND Services National coverage for installation Our professional construction teams are constantly travelling throughout New Zealand for our clients. We have panel manufacturing plants in Auckland and Christchurch and regional ofces in Mt Mauganui and Dunedin ensuring our staff and products are always readily available. The exibility to engage in building works from design assistance and build through to a subcontract capacity To ensure our customers get the most benets from the construction spectrum, we are comfortable in assisting with a full design and build service though to being engaged in a sub-contract capacity. No job is too big or too small. Experienced, professional, construction staff From estimating through to practical completion we have a commitment to doing it once, doing it right, to specication, on time, and in full. Competitive supply rates We can provide xed prices and short lead times. We also offer the full range of components for constructing insulated panel buildings. Warranty and certication Because weve been around for four decades, we stand by our workmanship, products and brands. Technical information and CAD details Are all available online at www.bondor.co.nz or call us for a hard copy. Insurance and re rating requirements for insulated panel can be confusing contact one of our technical or sales staff for some balanced advice. XFLAM To consolidate our position as a market innovator, we have adopted XFLAM as one of our leading brands. XFLAM is a globally developed re rated insulating material that delivers exceptional solutions for the construction of temperature controlled and energy efcient buildings. At Bondor New Zealand, we are committed to a healthy environment; our products are truly green and sustainable, both in form and functionality. We strive to ensure that the sustainability features of our products are the best for people, prots and the planet. Uses Bondor NZ structural insulated panels have been produced in New Zealand for more than 40 years during which time have been used in the following applications: Controlled atmosphere storage, freezers, chillers, roong, architectural cladding, high rise apartments, facades, distribution centres, gymnasiums, portable buildings, interior t outs, partitions, commercial kitchens, produce storage, wineries, temperature controlled environments, laboratories, blast freezers, supermarkets, food processing facilities, dairy factories, rearing sheds, cow sheds, residential roong, pharmaceutical manufacture, piggeries, sh processing, canopies, bakeries, archives, swimming pools, stadium roofs, incubation facilities, poultry sheds, kennels, housing, warehouses with ofces. Passive temperature control Fully encapsulated pre-nished panels containing Bondor New Zealands range of insulating core materials provide a guaranteed and continuous insulation rating, suitable for all ambient and refrigerated applications. When used as a roong product radiant heat transfer and condensation build up is eliminated. Flexible design Bondor New Zealands insulated panel can clad vertically or horizontally. There are three different prole nishes and two roof proles that can be combined with a wide choice of colours, including metallics, and specialist paint nishes suitable for both interior and exterior applications. Cost effective spanning capabilities Insulated panels provide excellent spanning capabilities and are self supporting to long lengths. Suitable for both load bearing and non-load bearing applications the structural detail and framing requirements are minimal when compared to other roof and cladding products. Seismic Performance The lightweight modular nature of Bondor Panel, particularly with and EPS or XFLAM core, produces minimal lateral loading during an earthquake. This force is comfortably accommodated by the high bracing capacity of the panel and the high strength of the steel facings and associated xings. The steel skin also provides signicant protection from falling objects. The structural couplings and xings are accessible for post event damage inspection and repair. Fire rated Choose from the range of Bondor New Zealands panel cores to meet the requirements of global insurers and the standards required in the New Zealand and Australian Building codes. The ranges of cores have been comprehensively tested. Bondor New Zealands Mineral Wool and XFlam panels meet the requirements of the NZBC for a 30 or 60 minute re rating (FRR) as well as FM Global 4880 Class 1.
Fast build times The modular nature of insulated panel can signicantly reduce build times. The Slip Joint panels arrive on-site pre-nished and are installed efciently using single x construction techniques. There are no curing times and no multi-product combinations to cause delays. Made in New Zealand Bondor panel is made in state- of-the-art manufacturing plants in Auckland and Christchurch. All panels are manufactured to the required length ensuring continuous watertight panels and no waste. Production exibility, the fast turn around of orders, and short runs are a feature of Bondor New Zealands manufacturing capabilities. Bondor New Zealands unique position of having operations in both islands minimises transport, thus reducing one of the contributors to global warming. Advanced insulation ratings Bondor New Zealands panel thicknesses provide a simple solution to achieving a full spectrum of insulation ratings greater than the requirements of the Building Code. Through improving the insulation values, the amount of fuel or energy required to heat or cool a building is reduced, beneting the environment and providing savings to the building user. Energy efcient Green buildings The efcient control of energy within the nished building and the short build times offset the minimal environmental impact of the panels manufacture and installation. Ongoing energy savings are made through outstanding climate control, provided by the panels continuous insulation properties, reducing heating, refrigeration and air conditioning costs. All Bondor New Zealand insulation cores can be recycled or remanufactured at the end of their useful life. Low maintenance and hygienic The steel proles and paint nishes provide an easily cleaned, hygienic, low maintenance sterile surface approved for food processing, food preparation and cool storage facilities. F A D C B E D C E B F F A Prenished steel skin Insulating core Female slip joint Male slip joint Easy & effective slip joint installation Rigid weathertight connection provides continuous insulation and resistance to re deformation Slip Joint technology Every panel incorporates Bondor New Zealands Slip Joint technology. This uniquely designed system incorporates a male and female joint on each steel face that provides a rigid and sealed connection between adjacent pawhe tightness and quality of the joint resists deformity in re situations, provides a weathertight seal and enables effective and easy installation. THE ADVANTAGES OF BONDOR NEW ZEALANDS STRUCTURAL INSULATED PANEL CREATING NEW DIMENSIONS in SUSTAINABLE BUILDING TECHNOLOGY WALLS, CLADDINGS AND FACADES
Wall panels can be installed horizontally or vertically. Finished panels can be any combination of wall prole. PANEL PROFILES FLAT SHADOWLINE EPS, MINERAL WOOL or XFLAM CORE EPS, MINERAL WOOL or XFLAM CORE EPS, MINERAL WOOL or XFLAM CORE 5 0 - 3 0 0 m m 5 0 - 3 0 0 m m 5 0 - 3 0 0 m m EFFECTIVE WIDTH 1200mm EFFECTIVE WIDTH 1200mm EFFECTIVE WIDTH 1200mm RIBBED Micro Ribbed EPS, MINERAL WOOL or XFLAM CORE EPS, MINERAL WOOL or XFLAM CORE EPS, MINERAL WOOL or XFLAM CORE 5 0 - 3 0 0 m m 5 0 - 3 0 0 m m 5 0 - 3 0 0 m m EFFECTIVE WIDTH 1200mm EFFECTIVE WIDTH 1200mm EFFECTIVE WIDTH 1200mm EPS, MINERAL WOOL or XFLAM CORE 5 0 - 3 0 0 m m EFFECTIVE WIDTH 1200mm THE RANGE Bondor New Zealands range of structural insulated panel technologies provide systems that enable the fast and cost effective construction of energy efcient, controlled environment, and re rated buildings. SATINLINE Microcorrugate EPS, MINERAL WOOL or XFLAM CORE EPS, MINERAL WOOL or XFLAM CORE EPS, MINERAL WOOL or XFLAM CORE 5 0 - 3 0 0 m m 5 0 - 3 0 0 m m 5 0 - 3 0 0 m m EFFECTIVE WIDTH 1200mm EFFECTIVE WIDTH 1200mm EFFECTIVE WIDTH 1200mm Satinline XFLAM Panel installed horizontally Flat EPS Panel installed vertically Titania EFFECTIVE WIDTH 1000mm EPS, MINERAL WOOL or XFLAM CORE EPS, MINERAL WOOL or XFLAM CORE 5 0 - 3 0 0 m m 5 0 - 2 5 0 m m 250mm 33mm 5 0 - 2 5 0 m m EFFECTIVE WIDTH 1000mm 250mm 32mm 34mm EFFECTIVE WIDTH 1000mm 1018mm EPS EFFECTIVE WIDTH 1000mm EPS, MINERAL WOOL or XFLAM CORE EPS, MINERAL WOOL or XFLAM CORE 5 0 - 3 0 0 m m 5 0 - 2 5 0 m m 250mm 33mm 5 0 - 2 5 0 m m EFFECTIVE WIDTH 1000mm 250mm 32mm 34mm EFFECTIVE WIDTH 1000mm 1018mm EPS METRIC 5-Rib Bondor NZs prenished metric roong panels are a fully insulated through xed roof and ceiling system that is extremely fast to install requiring only one trade.
The external continuous uniform end lap combined with an internal slip joint detail and insulated core provides an instant weather tight and thermally efcient roof with a prenished ceiling.
Metric roong panels offer many advantages over traditional built up systems including reduced installation costs, improved levels of air tightness and no risk of condensation or cold bridging.
With better spanning capabilities and fewer purlins than traditional long run roong, the installation time is reduced and the requirement to install underlays, foils, building papers, mesh and blankets is eliminated.
Savings of up to 25% can be made on both material and labour in comparison to conventional roong systems.
Ideal for where exposed rafters and purlins are detailed and for residential applications a thickness between 150mm and 200mm is recommended. North Island Prole South Island Prole Metric XFLAM Metallic Silver Metric EPS Titania ROOFING AND CANOPIES XFLAM
XFLAM is a breakthrough product in the eld of re-resistant panel.It is a syntactic foam with enhanced re resistance, excellent mechanical properties, superior insulation values, low toxicity and is completely recyclable. XFLAM combines the best attributes of Polyfoam EPS and phenolics with new attributes of its own.
Developed initially as a high performance core for panel systems, XFLAM also has applications in many other areas. XFLAM provides the following benets: XTRA Fire Resistance and Fire Ratings XFLAM consists of EPS pre-expanded beads with a hybrid phenolic resin, a catalyst, lightweight additives and carbon. The resin has high adhesive bond energy. It is hard to break down under re energy and eliminates the exposure of the EPS bead to the ame source. At 1200C the phenolic honeycomb matrix remains intact and the re behaviour is limited to surface charring which signicantly delays the re spread and protects the core. In comparison to other RCPs (rigid cellular plastics) such as PIR (polyisocyanurate and PUR (polyurethane) XFLAM provides superior re resistance. It achieves its FM Approval with simple and cost effective construction details and is the only RCP that achieves a Group 1 BCA classication.
XFLAM meets global insurance requirements: Factory Mutual Global. FM Wall - Ceiling Construction. Reference 3035839 Bondor New Zealand Ltd, 3025087 and 3029819 Austral Comnia Holdings PTY Ltd. Meets all the requirements of FM Approvals Standard 4880 for Metal-faced Building Insulations. Class 1 Fire Rated to max 9.1m High. Test Standard UBC 26.3.
XFLAM meets the NZ and Australian building codes for re resistance: AS1530.4 Fire Resistant Test: 50mm panel - /120/15 INTEGRITY RATING 120mins INSULATION RATING 15mins 100mm panel - /120/30 INTEGRITY RATING 120mins INSULATION RATING 30mins 250mm panel - /120/115 INTEGRITY RATING 120mins INSULATION RATING 115mins ISO9705 Corner Room Test achieved Group 1 BCA Classication. Passes the Flame Barrier requirements for foamed plastics under the Acceptable Solution C/AS1 part 6 of the NZBC.
Speciers and building owners can be condent when they use XFLAM they are fullling the requirement of the New Zealand and Australian Building Codes, Territorial Authorities and the insurance industry. TM Fire Rated & Architectural Panel Systems PANEL CORES XFLAM CREATING NEW DIMENSIONS in SUSTAINABLE BUILDING TECHNOLOGY XTRA Thermal Performance As an insulating material XFLAM achieves a higher insulation rating than EPS or mineral wool. Very low water transmission rates ensure XFLAM can be used in any application previously regarded as the preserve of EPS, PUR, and PIR panel. Greater insulation value reduces the energy costs for maintaining comfortable and efcient environments in the building. XTRA Strong As a construction product XFLAM has superior mechanical properties to EPS, PIR, PUR and mineral wool. It can span up to 30% further than PIR and PUR reducing the cost of supporting structures and freeing up internal spaces. XFLAM provides extra strength and rigidity that enables long spans suitable for use in the walls, ceilings, roofs and facades of all buildings. XFLAM can be used as structural unit in commercial and residential construction. XFLAM is suitable for use as trafcable ceiling. Structural costs can be signicantly reduced through using XFLAM panel, in comparison to other building materials and insulated panels. XFLAM does not require extra structural components to achieve its re ratings. XTRA Sustainable No blowing agents are used in the manufacture of XFLAM. XFLAM waste can be returned to the manufacturing process, and because its made locally, the carbon footprint of transport is minimal. Its advanced insulation ratings ensure that energy consumption is reduced preserving the natural resources of the planet. Sustainable construction is a critical factor in the consideration of building materials. XFLAM insulated panel ticks all the boxes and more. XTRA Safe XFLAM is compliant with both aircraft and underground rail re response requirements. In a re situation combustion is restricted to small clean burning cells with very little smoke production and negligible toxic species. Construction teams can easily work with XFLAM - protective work wear is not required. XTRA Stable Extruded rigid cellular plastics such as PIR and PUR commonly suffer from out gassing, a post-production phenomenon that results in signicant loss of thermal insulation over time and deformation of the panel and the likely release of toxic compounds into the environment. XFLAM like EPS, provides a stable and guaranteed thermal rating and is harmless and inert at the time of its manufacture into panel. XTRA Value Dollar for dollar, XFLAM achieves better thermal resistance (R-value) than PIR and PUR systems. Savings of up to 30% can be made when calculating the costs of the panel system and the appropriate structural supporting elements together. When considering the total construction cost of building, XFLAM offers signicant cost savings in the reduction of structural elements while offering superior insulation values in comparison to other RCPs. PANEL CORES XFLAM Mineral wool is manufactured from molten rock, glass or slag that is spun into wool-like bre and bound with resin. The bres are compressed which trap air creating insulation and sound control attributes. Classied as non-combustible, mineral wool does not conduct heat and can withstand temperatures above 1000C. Where noise control is important mineral wool provides signicant acoustic ratings. The inorganic nature and bonded structure of mineral wool makes it vermin and insect proof. Recommended for complete buildings, constructing re cells, partition walls, and isolating plant rooms where the ambient temperature is above 5C. Suitable also for cool stores and freezers with correct installation, and vapour barrier installed. At the end of its useful life, mineral wool can be reprocessed or returned to the earth without further containment. PANEL CORES EPS: MINERAL WOOL MINERAL WOOL Polyfoam EPS is the industry proven core used in insulated panel construction for more than 40 years including the original Rudnev panel. It is ideally suited in temperature control applications and has an impressive strength to weight ratio. Polyfoam EPS is the cost effective solution to rising building costs and its exceptional lightweight properties provide further savings in the costs for foundations, framing and installation. EPS has a signicant sustainable advantage in that it is completely recyclable. Bondor New Zealands Polyfoam EPS panel meets the NZBC acceptable solution C/AS1 for foamed plastics, and when detailed to Bondor New Zealands tested specication achieves a re resistance 240/240/- rating for non-load bearing walls. The raw material used contains a re retardant that is self- extinguishing. Burning it only results in water vapour, carbon dioxide and trace levels of ash similar to paper, and is less harmful than burning timber. In normal conditions energy saved in the rst six months of a building constructed from Polyfoam EPS panel is more than the total energy used to manufacture Polyfoam EPS and convert it to an insulating material. Polyfoam EPS has a low carbon footprint. It is a by- product obtained during the rening process of crude oil. The main component used in its manufacture as an insulating material is steam with any waste water being recycled back through the steaming process. Suitable for extreme environments. POLYFOAM EXPANDED POLYSTYRENE (EPS) Insulated Panel Insulated Panel Insulated Panel CORE COMPARISONS TABLE 1 FIRE PERFORMANCE XFLAM MINERAL WOOL EPS (Polyfoam) Insurer Approved Yes FM 4880 Class 1 Yes FM 4880 Class 1 Yes Can depend on risk assessment Fire rating of elements AS 1530.4 BS 476 pt22-24 LPS 1208 and equivalents - / 120 / 15 50mm panel - / 120 / 30 100mm panel - / 120 / 115 250mm panel - / 60 / 60 100mm panel - / 120 / 90 150mm panel - / 240 /240 200mm panel - / 240 / 0 100mm panel Flame barrier NZBC C/AS1 part 6 Yes Not required. Not a foamed plastic Yes ISO 9705 BCA Classication Group 1 Group 1 Non-Combustible Group 1* & 2 SMOGRA SMOkeGrowthRAte 2.2 NA 3.8 Toxicity Very Low CO, CO2 Non Flammable Low CO, CO2, C * Specic construction system required. TABLE 2 ENGINEERING DETAILS (Core material only unless otherwise stated) XFLAM MINERAL WOOL EPS (Polyfoam) Density 32 kg/m 3 100 kg/m 3 16 kg/m 3 Water absorption ASTM C272 Very Low NA Very Low Crushing / compressive strength to 10% deformation 156kPa 60kPa 83kPa Cross breaking strength 240kPa NA 186kPa Thermal conductivity (see table 4) 0.032 W/mK 0.041 W/mK 0.042 W/mK Thermal Control (see table 4) Best Good Better Recyclable Yes Reusable Yes Workability Excellent. No requirement for protection. Resistant to pedestrian trafc (1 person/m 2 ) Protective clothing and dust masks recommended. No pedestrian trafc crawl boards required. Excellent. No requirement for protection. Resistant to pedestrian trafc (1 person/m 2 ) Span capabilities of panel. See Table 6 Best Good Better Acoustics of panel 25 STC 30 STC 22 STC CREATING NEW DIMENSIONS in SUSTAINABLE BUILDING TECHNOLOGY Operating Temperatures C XFLAM MINERAL WOOL EPS (Polyfoam) 7.0 down to 3.0 75mm 75mm 75mm 3.0 down to -3.0 100mm 100mm 100mm -3.0 down to -18.0 125mm 150mm 150mm -18.0 down to -23.0 150mm NA 175mm -23.0 down to -30.0 175mm NA 200mm TABLE 5 THICKNESS FOR CHILLERS AND FREEZERS Allow an additional 50mm thickness for walls and roofs exposed to direct sunlight. Consideration should be given to insulating oor detail. Values are guides only and are given for cool rooms operating under average ambient conditions. TABLE 6 SPAN DATA For the complete range of panel spans versus load, refer to Bondor New Zealands Design Guide. Spans are indicative only and apply to wall and roof proles using 0.59BMT steel, specic site conditions need to be calculated by an Engineer. For canopies and snow load use AS1170.3. For wind speed direction refer to code AS1170.2 regions A6 and A7 and W, by default use 1.00Kpa, note wind pressure depends on life of building. *0.50kPa loading takes account of re load. Specic engineering is required for excessive cantilevered applications. Internal Wall & Ceiling 0.50kPa* External 0.75kPa External 1.00kPa Internal Wall & Ceiling 0.50kPa* External 0.75kPa External 1.00kPa Internal Wall & Ceiling 0.50kPa* External 0.75kPa External 1.00kPa 50mm 6.3 5.1 4.5 2.9 2.4 2.1 5.0 4.0 3.5 75mm 7.7 6.3 5.5 4.0 3.3 2.9 5.9 4.9 4.4 100mm 8.9 7.3 6.3 5.0 4.1 3.5 6.9 5.6 5.0 150mm 10.9 8.9 7.7 6.4 5.3 4.6 8.5 7.0 6.1 200mm 12.6 10.3 8.9 NA NA NA 9.6 8.0 7.0 250mm 14.1 11.5 10.0 NA NA NA 10.5 8.8 7.8 XFLAM MINERAL WOOL EPS (Polyfoam) CORE COMPARISONS Continued REV: February 2011. REPRINTED: February 2011. TABLE 3 NOMINAL WEIGHTS (kg/m2) TABLE 4 THERMAL RESISTANCE (R Value at 15 o c) R values are conservative and are based on the core properties alone. Weights based on panels with 0.6BMT steel wall and faade proles. XFLAM MINERAL WOOL EPS (Polyfoam) 50mm 12.7 15.8 11.6 75mm 13.7 18.3 12.0 100mm 14.6 20.8 12.3 150mm 16.5 25.8 13.1 200mm 18.4 NA 13.9 250mm 20.3 NA 14.7 XFLAM MINERAL WOOL EPS (Polyfoam) 50mm 1.61 1.20 1.31 75mm 2.42 1.83 1.96 100mm 3.22 2.44 2.62 150mm 4.84 3.66 3.92 200mm 6.45 NA 5.23 250mm 8.06 NA 6.54 WARRANTY Bondor New Zealand Ltd typically supply a 15 year product warranty, and a 2 year labour warranty subject to design conditions and maintenance. Contact Bondor New Zealand or refer to Bondor New Zealands Design Guide or Maintenance Guide for further information. 1. Details and specications in this brochure may change without notice. 2. While every care has been taken to ensure the accuracy of information no responsibility will be accepted for any errors or ommissions. 3. All information supplied applies only to products manufactured, supplied and tested by Bondor New Zealand Ltd and companies owned by Austral Comnia Holdings PTY Ltd. Use of the information in this document for generic specication is a breach of copyright. Substitution with other panel manufacturers products may contravene The Building Act 2004, and is at the buyers risk. TABLE 7 DIMENSIONS AND TOLERANCES Building Component Prole Effective Cover +-1mm Min. Length +-5mm Min. Roof Pitch WALLS CEILINGS Flat, Ribbed, Satin Line 1200mm 1200mm NA ROOFING Metric Min thickness 150mm for residential 1000mm 1200mm 3 o Bondor NZ All Weather Roof (Pan) 1o00mm 1200mm 4 o Freezer Roof / Flat Fully supported 1200mm 1200mm 3 o Roof pitches will very depending on site conditions, loads, purpose, conguration, snow loading and span requirements. Under the building code insulated panel used as a cladding is an Alternative Solution and requires specic design. In a roong application Bondor NZ panel satises the requirements of the NZBC External Moisture-Clause E2, when correctly specied and installed with ashings which direct the ow of water away from the building envelope. MANUFACTURING PROCESS Bondor New Zealands insulated panel manufacturing process roll forms & laminates two skins of steel to the selected core using a CFC-free two part thermosetting polyurethane system applied in a controlled temperature environment. CORE COMPARISONS Continued Contact Bondor New Zealand or refer to Bondor New Zealands Design Guide or Maintenance Guide for further information. 0800 430 430 Email info@bondor.co.nz Website www.bondor.co.nz BAY OF PLENTY 11/19 Rerewai Place, Mt Maunganui. 3116 Telephone: 07 574 3246 Fax: 07 572 0922 DUNEDIN 137 Main South Road PO Box 13-057, Dunedin 9013 Telephone: 03 488 3087 Fax: 03 488 1731 AUCKLAND 60 ORorke Road, Penrose PO Box 11-169, Ellerslie, Auckland 1061 Telephone: 09 580 6600 Fax: 09 580 6616 CHRISTCHURCH 51 Buchanans Road, Sockburn PO Box 11-106 Christchurch 8042 Telephone: 03 342 8890 Fax: 03 342 6176 EXPANDED POLYSTYRENE INSULATION All information contained in this brochure is available in PDF format at www.bondor.co.nz REVISED AND REPRINTED JULY 2011