Hebel Supercrete AWS Design Guide

AWS 2009 Version 1.
Acoustic Wall Systems Design Guide
NONTOXIC
ENERGY SAVING
LIGHT WEIGHT
NOISE RESISTANT
FIRE RESISTANT
ACCURATE
VERSATILE
LONG LIFE
RAPID ASSEMBLY
EASILY WORKED
BREATHABLE
Coatings Ltd
Acoustic Wall Systems Design and Installation guide

This Design and Installation Guide is for acoustic wall panel systems, used primarily for intertenancy walls. However, the increasing popularity of home theatre systems is also generating a requirement for acoustic walls in residential homes. The options detailed in this design guide are suitable for single or multiple occupant residential or commercial use. The design of acoustic walls is a specialized field and normally requires the services of a professional consultant. This guide has been prepared for their assistance but in no way replaces the services of a professional consultant on the project.
Contents
1.0 Introduction 1.1 What are Hebel Supercrete Acoustic Wall Systems? 1.2 Why choose AWS? 1.3 Availability 1.4 Panel sizes Benefits Acoustic Performance 3.1 Definitions 3.2 NZ Building Code Requirements 3.3 Acoustic Analysis Selection of AWS Type Fire Rating Performance 5.1 Fire Resistance Rating (FRR) of AWS Walls 5.2 System Variations 3 3 3 3 4 5 11.0 3.0 6 6 6 6 7 15 15 15 12.0 Delivery & Storage AWS Construction Details 12.1 Hebel Supercrete Panel Construction Details 12.2 Junction Details 12.3 Roof Details 12.4 Control Joint Details 12.5 Wet Area Wall Details 12.6 Door Details 12.7 Penetration and Services Details 23 24 24 27 29 30 30 31 32 7.0 8.0 9.0 10.0 2.0 Design & Installation Considerations System Components Installation of AWS Walls Panel Handling 17 18 20 22
4.0 5.0
6.0
Structural Performance 16 6.1 Structural Performance 16 6.2 High Lateral Loading 16 6.3 Wall Heights 16 6.4 Cutting of Hebel Supercrete Panel16 6.5 Steel Stud Frame 16 6.6 Custom Hebel Supercrete Panel 17 6.7 Fastenings 17 6.8 Lightweight Support Framing 17
Appendix A: A1 Hebel Supercrete Panel Material Properties 33 A2 Proforma Architectural Specification 34 A3 Installation Checklist 35 Health and Safety, Performance & Certification, Guarantee & Disclaimer
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1.0 Introduction
1.1 What are Hebel Supercrete Acoustic Wall Systems?
Hebel Supercrete Acoustic Wall Systems (AWS) have been developed to satisfy the ever increasing demand for noise abatement in residential and commercial applications. They are based on the use of 75 mm thick Hebel Supercrete Panel, with or without various combinations of steel framing, lining and supplementary insulation, depending on the acoustic requirement of the wall. These are used to create wall systems which have minimal components and are relatively compact. The resulting walls exhibit high acoustic insulation performance, proven by both laboratory testing and successful applications throughout Australia and New Zealand. There are four basic wall systems detailed in this guide which all equal or exceed the requirements of the New Zealand Building Code (NZBC). Wall systems with lesser acoustic performance have not been included. Any of the systems can be varied to suit individual requirements. Hebel Supercrete Panels are made from Autoclaved Aerated Concrete (AAC), manufactured from sand, lime and cement, to which a gas forming agent, in the form of aluminum paste, is added. The liberated gas expands the mixture, forming small finely dispersed air bubbles, resulting in a lightweight concrete approximately one quarter of the weight of traditional concrete. It has a dry density of 500 kg/m3 (density at 30 % moisture content is 680 kg/m3) The AAC is cast in 6.0 x 1.5 x 0.6 m blocks with reinforcing cages held in the correct place for individual panels. This block is then sliced with taught steel wires after the initial set, and the whole block is then cured and crystallized in an autoclave. constructed to the bare minimum are usually lower in cost, but represent poor value for money. Some common systems consist of double timber or steel frames lined with fire resistant plasterboards, others are solid masonry or concrete tilt slab type construction. Timber framed solutions generally have lower fire ratings as they are combustible and wholly reliant on the lining to protect the frame. Steel frames also have low resistance to heat and can buckle under load. Lower fire rated walls may require sprinkler systems within the structure, and although these help protect human life, the end result of a fire in such a structure often means that the framed wall must be completely replaced after such an event. Also, these double frames and their multiple linings can take up a lot of floor space, frequently over 300 mm in width. Masonry and dense concrete walls are slow to construct, and heavy, adding mass and bracing demand to the structure. They need additional strapping, lining and insulation to achieve minimum acoustic requirements. Tilt slabs are difficult to install between existing floor slabs, because of their large size, shape and weight. The Hebel Supercrete Acoustic Wall Systems (AWS) overcome these inherent difficulties in achieving a high performance intertenancy partition. The Hebel Supercrete systems are slender, fire rated, with fast construction times, and with sound transmission reductions that exceed the NZ Building Code requirement. Hebel Supercrete panels are non combustible and provide 3 hour fire ratings. They are only one quarter of the weight of dense concrete and are easily manhandled into place. They can be easily cut on site making installation around beams, ducts and services much simpler than conventional dense concrete tilt slabs. The systems selected for this design guide are practical, economic solutions for walls requiring excellent acoustic performance and fire protection.
1.2 Why choose AWS?

There are many different ways of creating an acoustic barrier between adjoining tenancies, which will meet New Zealand Building Code minimum requirements. Selection of the appropriate acoustic wall system can also depend on the required fire resistance rating and whether the system must be load bearing or have bracing capacity. Overall wall thickness can also govern the choice of wall system. Often, the acoustic rating desired will be more than the minimum code requirement. Many building owners are disappointed with the performance of buildings constructed with only the minimum acoustic insulation and it is often difficult to increase the acoustic insulation retrospectively. Walls 3
1.3 Availability
Hebel Supercrete Panel is manufactured by CSR Hebel Australia in a factory at Somersby, north of Sydney. CFG Concrete Ltd is the sole importer of Hebel Supercrete Panel into New Zealand, and has a network of distributors throughout the country for supply, liaison and backup support. Refer to the CFG Concrete Ltd website (www.hebel.co.nz) for your nearest distributor. Because of the bulk quantities of panels purchased by CFG Concrete Ltd, the landed price in New Zealand is often less than similar panels purchased in Australia, and are hence priced very competitively.
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1.4 Panel Sizes

All 75 mm Hebel Supercrete Panel is manufactured in standard widths of 600 mm with a plain edge profile. Panels are available in several lengths between 2.4 and 3.0 metres. See Table 8.2 for available sizes. Panels can be easily site cut for other heights, widths, complex shapes, or services. For walls higher than 3.0 metres, custom panel can be manufactured up to a 3.9 metre height in the 75 mm thickness. 100 mm panel is also available in 600 mm or 450 mm width and lengths up to 3.2 metres for specific designs refer to CFG Concrete Ltd. Custom panels can have a tongue and groove edge profile. Note that there is a longer lead time required on custom panel as these are manufactured specifically for each design.
Fig 1.1 Hebel Supercrete Panel Trolley makes on-site manoeuvring quick and simple.
Fig. 1.2 Hebel Supercrete Panel is easily handled by two people in this Type 3 application
Figure 1.3 Hebel Supercrete Panel installed on the ground floor of an intertenancy wall in a Type 1 Wall
Fig. 1.4 Second storey panel installation in a Type 1 Wall Fig. 1.5 Awaiting installation of base track and panels for second storey of intertenancy wall in Type 1 Wall
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2.0 Benefits
The many benefits of using Hebel Supercrete AWS systems include: Acoustic Performance: Significantly reduced sound transmission between units and rooms. Good Impact Noise Resistance: All Hebel Supercrete AWS walls have good impact noise resistance due to separated wall construction. Lightweight: Lighter loads on structures compared to masonry block, for equivalent STC rating. Slender Walls: Wall thicknesses range from 171 to 256 mm. Cost Effective: Cost savings compared to traditional masonry construction. No Wet Trades: Less mess and a cleaner, safer work area. Less Wastage: Greatly reduced waste, as panels are available in a range of standard lengths. This allows for best-suited panel length selection, which eliminates or reduces off-cut waste. For a small price premium panels can be manufactured to specific lengths for large scale projects. Speed of Construction: Fast installation and assembly speeds with smaller construction crew requirements. Fire Protection: AWS systems have excellent fire rating properties and can achieve the highest code rating of 4 hours. Security: Steel reinforced AAC panels provide a high degree of security between units. Thermal Resistance: Excellent thermal insulation for energy savings between adjacent rooms. Design Flexibility: Lighter weight allows increased spans, reduced column sizes and/or reduced beam depths. Ease of cutting allows complex shapes to be acoustically isolated. Technical Support: Competent technical staff can assist with systems information. The photos below show some of the projects that have used Hebel Supercrete AWS walls internally.
Mariners Cove
The Vie Apartments
Elma Apartments
Metropole Apartments 5
Harbour Watch Apartments

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3.0 Acoustic Performance

3.1 Definitions
There are a number of rating systems for defining the effectiveness of a wall for sound insulation. The New Zealand Building Code uses the Sound Transmission Class (STC) but some other regulatory authorities use the Weighted Sound Reduction Index (Rw). Sound Transmission Class STC The STC value is a single number used to rate acoustic walls based on tests in an acoustic laboratory, where a test wall is constructed between two rooms that are acoustically isolated from each other. A sound is generated in one room and the sound level in the other room is measured, for frequencies between 100 Hz and 5000 Hz. The sound level differences are then normalized to allow for differences in various parts of the receiving room and for the absorption factor in the walls. These normalized values at each frequency band are compared to standard performance graphs where only a limited portion of the graph of sound loss is permitted to fall below the standard curve and the class is given by the highest standard contour line which is the best fit to the tested curve. The STC value is given by the value at 500 Hz on the best fit curve. Effectively, it is the expected loss in decibels through the wall under laboratory conditions. In reality, actual sound reduction in site conditions is usually less than the STC value due to flanking sound paths and other factors. The NZBC allows a 5 decibel reduction from the STC laboratory rating under site conditions. The STC is the system developed by the American Society for Testing and Materials (ASTM International). Weighted Sound Reduction Index Rw The Rw is a weighted STC value where a correction factor is added to the STC value to take into account performance at lower frequencies. The Rw is a European system and is not currently used in the NZBC, but it is gaining acceptance in many other countries. Typically, the Rw value is one or two decibels less than the STC value, as the correction factor is usually negative. Impact Isolation Class (IIC) The IIC is usually used for floors only, but can be applied to walls. It quantifies the transmission of impact sound through a floor or wall. The test involves measuring the sound loss through a panel in a similar test setup as for the airborne sound in the STC test, but where the sound on one side is generated by a standard tapping machine. Higher numbers indicate less sound is being transmitted. The IIC is an American system which is gradually being replaced by the Ln,w value which is the ISO equivalent, but the NZBC at time of printing, still uses the IIC. Acoustic Opinions Sound Transmission Classes for specific configurations of walls are determined by professional acoustic consultants from computer models based on available test data with a 96% confidence of being within 2.5 decibels of a tested wall. These results are referred to as opinions as it is unrealistic to test every possible wall configuration.
Fig. 3.1 Best Fit of partition wall test result to standardised curves (STC60 standardised curve is the highest curve fitting the results)
85 80 75 70 65 60 55 50 45 40 35 30 25 20 100 125 160 200 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000
Sound Transmission Loss. STL (dB)
STL curve of test wall STC60 STC55 STC50 STC45
1/3 Octave Band Centre Frequency (Hz)
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3.2 NZ Building Code Requirements

Clause G6 of the NZBC requires that common walls between different occupancies must have an STC value of 55 or more, and that the IIC between floors must be at least 55. The NZBC allows the site performance of a wall when tested to have a STC a maximum of 5 decibels below the laboratory test value.
3.3 Acoustic Analysis

Increasing the STC rating of a particular wall system is possible by varying types of lining on one or both sides of the panel, varying cavity widths, and varying supplementary
insulation. However, acoustic analysis is not straight forward as different densities of material will absorb different frequencies of sound, and combinations of different materials will act differently again. The STC for each layer of a wall cannot therefore be added together, to give a total STC for the wall, as the STC is a value based on all frequencies in the test range. It is recommended that you seek advice from an acoustic consultant where the acoustic performance of the wall must achieve a set STC. Remember that the site performance of the wall may be less than the laboratory test or opinion as it will be affected by the presence of flanking paths, quality of installation, detailing of wall junctions and services, room sizes and shapes, and floor construction. Note that a bare 75 mm Hebel Supercrete Panel will have an STC rating of 37.
4.0 Selection of AWS Type

Table 4.1 Systems Index for Hebel Supercrete AWS Walls
Wall System Type TYPE 1 Low rise multi-residential. Used where full height intertenancy wall is required to isolate each side from fire transfer, as well as for acoustic performance. Load bearing, bracing applications Applications
Selection of the appropriate wall system depends primarily on the type of building construction and acoustic performance required. It can also depend on the finished wall thickness, fire rating, construction time and cost. The four types of Acoustic Intertenancy Wall Systems are summarized in Table 4.1 and specific details are shown in the following diagrams for each system.
Fire Rating*
STC
Thermal Resistivity R
Wall Thickness
90/90/90
63 to 67
5.5
305 to 331
TYPE 2
Used primarily for non load bearing walls between floors. Used where maximum floor space is to be achieved and where services on one side of the wall are to be concealed.
-/180/180* to -/240/240
61 to 64
3.0
171 to 193
TYPE 3 Used primarily for non load bearing walls between floors. Lightweight partition walls between units where services on both sides of the wall are to be concealed.
-/120/120*
56
5.2
245
TYPE 4
Used primarily for non load bearing walls between floors. Lightweight partition walls with ultra high acoustic performance. Used where a solid wall is required on both sides.
-/120/120* to -/240/240
64
2.8
200
*Depends on wall height refer Table 5.1 7

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Details to be read in conjuction with the current Hebel Supercrete Acoustic Wall Systems Design Guide, AWS 2009
Detail 4.1.1 Type 1 Wall System Full height Hebel Supercrete Panel intertenancy wall
Insulation to project specification
Timber or steel framing both sides
Services may penetrate decorative wall without fire caulking
Hebel Adhesive at edge joints See details for base options
Services must run through wall frame and must not be fixed to the Hebel Supercrete Panel No penetrations permitted through the Hebel Supercrete Panel
Plasterboard lining fixed with 25mm needle point screws. Use Gib Aqualine or similar in wet areas
Type 1 Wall System
* * * * * * * * *
Lining 1 Single layer of Plasterboard screw fixed/glued to framing 100mm nominal timber framing or steel framing equivalent 90mm R 2.0 minimum fibreglass insulation 10 to 20mm gap 75mm Hebel Supercrete panel, non loadbearing, steel reinforced AAC panel 10 to 20mm gap 90mm R 2.0 minimum fibreglass insulation 100mm nominal timber framing or steel framing equivalent Lining 2 Single layer of Plasterboard screw fixed/glued to framing Wall Width mm Fire Rating minimum All 90/90/90 System Variations Lining 1 10mm Plasterboard 13mm Plasterboard 13mm Gib Noiseline* 10mm Gib Aqualine* Lining 2 10mm Plasterboard 13mm Plasterboard 13mm Gib Noiseline* 10mm Gib Aqualine*
STC 63 64 67 63
All 305 to 331 Depending on timber size & lining type
* or equivalent products of similar density

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Detail 4.1.2 Vertical cross section of Type 1 Wall

Mineral fibre or other fire-resisting material as per project specifications if panel does not extend to underside of roofing
Bracket fixed to framing and panel (refer to fixing detail)
Refer to Detail Section 12
Bradford or similar insulation as per project specification
3000mm max. panel height
Bradford or similar insulation as per project specification Wall brackets each side of panel Bradford or similar insulation as per project specification 3000mm max. panel height 3000mm max. from bracket to bracket Floor joists may be perpendicular or parallel to wall Refer to horizontal joint detail Section 12 Hebel Supercrete Soundfloor AAC floor sheeting on joists
600mm max. from bracket to joint in panel
Additional noggings and clips required in offset floor level applications Bradford or similar insulation as per project specification Wall bracket 3000mm max. panel height Timber or steel framing as per project specifications 75mm Hebel Supercrete Panel 10-20 mm gap on each side
Base detail. Refer to alternative methods in Section 12
Concrete slab
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Detail 4.2 Type 2 Wall System 75mm Hebel Supercrete Panel with separated stud
22mm IBS rod Fill gap with fire and acoustic rated sealant to manufacturer's recommendations Fill gap with fire and acoustic rated sealant to manufacturer's recommendations Rondo deflection head tracks fixed to soffit at 600mm max. centres to project specifications Concrete soffit
Bradford or similar insulation to project specifications
75mm Hebel Supercrete Panel fixed edge to edge with Adhesive
Plasterboard lining fixed with 50mm bugle head coarse thread screws
Plasterboard lining fixed with 25mm needle point screws
Mortar as required between slab and panel
Fill 10mm gap with fire and acoustic rated sealant to manufacturer's recommendations Concrete slab Rondo steel studs and noggings to manufacturer's specifications Rondo base track fixed to floor to manufacturer's specifications Fix Hebel Supercrete Panel to base angle with 1 x 14-10 x 65mm hex head screw 50mm from each corner
Fill 10mm gap with fire and acoustic rated sealant to manufacturer's recommendations Rondo base angle fixed to slab at 600mm max. centres to project specifications
Detail 4.2.Type 2 Vertical cross-section

J-track or deflection head fixed to soffit Fire and acoustic rated sealant
22mm IBS rod Concrete soffit Fire and acoustic rated sealant
25mm needle point screws
50mm bugle head coarse thread screw
Plasterboard as per system requirements
Plasterboard as per system requirements 75mm Hebel Supercrete Panel
Rondo steel stud framing system
14-10 x 65mm hex head screw
Insulation as per system requirements
10mm fire and acoustic rated sealant
10mm fire and acoustic rated sealant Concrete slab
Mortar as required Rondo base angle fixed to slab Rondo track fixed to slab
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Type 2 Wall System
* * * *
Lining 1 Single layer of Plasterboard screw fixed to Hebel Supercrete Panel 75 mm Hebel Supercrete Panel (non loadbearing, steel reinforced AAC panel) 12 mm minimum gap Rondo or similar 64 mm steel studs at 600mm maximum horizontal centres. Fitted in deflection head track at soffit and base track at floor. * 75 mm fibreglass insulation infill * Lining 2 Single layer of Plasterboard screw fixed to steel studs Wall Width mm 171 177 181 181 184 193 Fire Rating (minimum) -/180/180 -/180/180 -/240/180 -/240/180 -/240/180 -/240/180 System Variations Lining 1 10mm Plasterboard 13mm Plasterboard 10mm Gib Aqualine* 10mm Gib Aqualine* 10mm Gib Aqualine* 16mm Gib Fyreline* Lining 2 10mm Plasterboard 13mm Plasterboard 10mm Gib Aqualine* 10mm Gib Aqualine* 10mm Gib Fyreline* 16mm Gib Fyreline*
STC 61 61 61 61 63 64
* Or equivalent products of similar density Note: Fire ratings may be higher depending on wall height. Refer Table 5.1
Fig. 4.1 Typical Type 2 wall installation
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Detail 4.3 Type 3 Wall System 75mm Hebel Supercrete Panel with double separated stud
22mm IBS rod Fill gap with fire and acoustic rated sealant to manufacturer's recommendations Rondo deflection head tracks fixed to soffit at 600mm max. centres to project specifications Plasterboard lining fixed with 50mm bugle head coarse thread screws Rondo steel studs and noggings to manufacturer's specifications Mortar as required between slab and panel Rondo base track fixed to floor at 600mm max. centres to project specifications Fill 10mm gap with fire and acoustic rated sealant to manufacturer's recommendations Rondo base angle fixed to slab at 600mm max. centres to project specifications Fill gap with fire and acoustic rated sealant to manufacturer's recommendations Concrete soffit Bradford insulation to project specifications 75mm Hebel Supercrete Panel fixed edge to edge with Adhesive
Plasterboard lining fixed with 25mm Type 'S' needle point screws
Fill 10mm gap with fire and acoustic rated sealant to manufacturer's recommendations Concrete slab
Rondo steel studs and noggings to manufacturer's specifications Rondo base track fixed to floor to manufacturer's specifications Fix Hebel Supercrete Panel to base angle with 1 x 14-10 x 65mm hex head screw 50mm from each corner of each panel
Fig. 4.2 Typical Type 3 wall installation
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Detail 4.3 Type 3 Vertical cross-section
22mm IBS rod
J-track or deflection head fixed to soffit
Fire and acoustic rated sealant
Concrete soffit Fire and acoustic rated sealant 25mm needle point screws
25mm needle point screws
Rondo steel stud framing system Plasterboard as per system requirements Insulation as per system requirements 14-10 x 65mm hex head screw 10mm fire and acoustic rated sealant Rondo track fixed to slab
Rondo steel stud framing system 75mm Hebel Supercrete Panel
10mm fire and acoustic rated sealant Concrete slab Mortar as required Rondo base angle fixed to slab Rondo track fixed to slab
Wall System Type 3 STC 56
* Lining 1 Single layer of 10 mm Plasterboard screw fixed to steel studs * Rondo or similar 64mm steel studs at 600 mm maximum horizontal centres. Fitted in deflection head track at soffit and base track at floor. * 12 mm minimum gap * 75 mm Hebel Supercrete Panel (non loadbearing, steel reinforced AAC panel) *12 mm minimum gap * Rondo or similar 64 mm steel studs at 600 mm maximum horizontal centres. * 50 mm fibreglass insulation infill * Lining 2 Single layer of 10mm Plasterboard screw fixed to steel studs
Wall width Fire rating Minimum
245mm
-/120/120
Note: Fire ratings may be higher depending on wall height. Refer Table 5.1
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Detail 4.4 Type 4 Wall System Double 75mm Hebel Supercrete Panel
Fill gap with fire and acoustic rated sealant to manufacturer's recommendations 22mm IBS rod Rondo deflection head tracks fixed to soffit at 600mm max. centres to project specifications 75mm Hebel Supercrete Panel fixed edge to edge with Adhesive Plasterboard lining fixed with 50mm bugle head coarse thread screws 30mm cavity Bradford insulation to project specifications Concrete soffit Rondo deflection head tracks fixed to soffit at 600mm max. centres to project specifications Plasterboard lining fixed with 50mm bugle head coarse thread screws Fill gap with fire and acoustic rated sealant to manufacturer's recommendations
Fill 10mm gap with fire and acoustic rated sealant to manufacturer's recommendations
Fill 10mm gap with fire and acoustic rated sealant to manufacturer's recommendations
Mortar as required between slab and panel Rondo base angle fixed to slab at 600mm max. centres to project specifications
Concrete slab
Fix Hebel Supercrete Panel to base angle with 1 x 14-10 x 65mm hex head screw 50mm from each corner. (Use 14-10 x 100mm MP bugle head screw when fixing from Hebel side)
Wall System Type 4 Detail 4.1 Type 4 Vertical cross-section

22mm IBS rod J-track or deflection head fixed to soffit Fire and acoustic rated sealant
STC Wall width Fire rating Minimum
64 200mm -/120/120
Concrete soffit Fire and acoustic rated sealant 50mm bugle head coarse thread screw
N10 x 50mm bugle head coarse thread screw
* Lining 1 Single layer of 10mm Plasterboard screw fixed to Hebel Supercrete panel * 75mm Hebel Supercrete Panel (non loadbearing, steel reinforced AAC panel) * 30mm minimum cavity between panels * 50mm fibreglass insulation * 75mm Hebel Supercrete Panel (non loadbearing, steel reinforced AAC panel) * Lining 2 Single layer of 10mm Plasterboard screw fixed to Hebel Supercrete Panel Note: Fire ratings may be higher depending on wall height. Refer Table 5.1
Plasterboard as per system requirements Plasterboard as per system requirements 75mm Hebel Supercrete Panel 75mm Hebel Supercrete Panel
14-10 x 100mm MP bugle head screw
Mortar as required
Concrete slab Rondo base angle fixed to slab
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5.0 Fire Resistance Performance

5.1 Fire Resistance Rating (FRR) of AWS Walls
Fire ratings for each wall type, dependant on height, are shown in Table 5.1. These are derived from CSIRO Fire Opinions FCO 2073 and FCO 2327 for Types 2, 3 and 4 and WFRA-45771.3 from Warrington Fire Research (Aust) Pty Ltd for Type 1 and are available from CFG Concrete Ltd if required. Most multi occupant structures are only required by the NZ Building Code to have a 30/30/30 minute fire rating for structural adequacy, integrity and insulation respectively. 75mm Hebel Supercrete Panel on its own has a fire rating of 180/180/180 minutes, so it is the detailing of fastenings that hold the panels in place and their protection from any outer linings, that will determine the fire rating of the acoustic wall. Note that the overall fire rating of a wall can be affected by any penetrations through the wall and the methods adopted to protect these penetrations. For example, a fire collar around a service pipe with a -/120/120 minute fire rating will restrict the overall fire rating of the wall to -/120/120 minutes, even if the wall panels have a fire rating of -240/240/240 minutes. Penetrations can be protected by fire rated sealants, intumescent fire collars, or fire rated mortars.
5.2 System Variations

Certain variations to the Hebel Supercrete AWS walls will not affect the fire-resistance levels listed in Table 5.1. However these variations need to be approved by the project fire consultant or project certifier. The possible variations to the systems include: 1) Changing the type or density of insulation; 2) The incorporation of gaps between the steel stud (51mm, 64mm, 76mm or 92mm deep steel studs) and the Hebel Supercrete Panel of up to 100mm maximum (Wall Types 2 and 3) 3) Cavity widths of up to 250mm between panels in double panel walls (Wall Type 4). Fig. 5.1 Hebel Supercrete Panels stay intact after the remainder of the building has burnt.
Table 5.1 Fire Resistance Rating of Hebel Supercrete AWS walls Maximum Wall Height (mm) Wall System Type Type 1 Type 2 Type 3 Type 4 Fire Resistance Rating (mins) -/60/60 12000 3900 3900 3900 -/90/90 12000 3900 3900 3900 90/90/90* 12000 N/A N/A N/A -/120/120 N/A 3900 3900 3900 -/180/180 N/A 3000 3000 3600 -/240/240 N/A N/A N/A 3000
Note: The values in Table 5.1 should be read in conjunction with CSIRO Fire Opinions FCO-2073 and FCO-2327, and WFRA45771.3 from Warrington Fire Research (Aust) Pty Ltd. *Wall Type 1 is the only structural load bearing wall system needing a structural adequacy value.
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6.0 Structural Performance

6.1 Structural Performance
Hebel Supercrete AWS Type 1 can either be loadbearing or non loadbearing. The Hebel Supercrete panel in the wall is non load bearing apart from self weight. All other Hebel Supercrete AWS wall types are non-loadbearing walls used in internal applications. The walls are designed to resist a maximum permissible uniformly distributed load (UDL) of 0.25kPa (this equates to an internal wind speed of 20m/s with a pressure coefficient of 1), and a deflection limit of H/240 (Height 240) or 20mm maximum.
6.5 Steel Stud Frame

The steel framing presented in this Design Guide for various wall systems has not been approved for the design parameters in this Design Guide. It is the designers responsibility to determine an appropriate steel framing system. Several items the designer must allow for are; lateral loadings, wall height, deflection limits, offset distance (gap) from the panel, building movement and control joint locations. As a minimum the wall will have a deflection limit of H/240. As a guide, CFG Concrete Ltd recommends providing a minimum gap distance of Height/240 + installation tolerance. For example, H = 2400mm and installation tolerance = 2mm, then minimum gap = 2400/240+2 = 12mm. This is to ensure that the two leaves of the cavity wall do not touch during service loading. Table 6.1 outlines the recommended minimum gap to suit a range of wall heights for the H/240 deflection limit. Table 6.1 Recommended minimum gap between the Stud Frame and the Hebel Supercrete Panel Wall. Wall* Height (mm) 2400 2550 2700 2850 3000 3200 3550 3900 H/240 (mm) 10 11 12 12 13 14 15 17 Minimum Gap (mm) 12 13 14 14 15 16 17 19
6.2 High Lateral Loading

For UDL loads greater than 0.25kPa the standard Hebel Supercrete Panel and associated components may not have sufficient capacity. These panels and components will have to be designed to ensure structural adequacy. CFG Concrete Ltd can confirm the adequacy of the panel and the project engineer can confirm the adequacy of the components such as deflection head, base angle, studs, furring channels and fixings.
6.3 Wall Heights

The overall wall height limit for Type 1 walls is 12.0 metres using standard Hebel Supercrete Panels up to 3.0m high. Panels greater than 3200mm in height should have the deflection head track replaced with two 50 x 50 x 1.2mm galvanised steel angles (see detail 12.1.9) and a 50 x 50 x 1.2mm galvanised steel angle at the base.
6.4 Cutting of Hebel Supercrete Panel

For the load parameters outlined above (UDL 0.25kPa), the standard Hebel Supercrete Panel can be reduced to a minimum width of 270mm without compromising reinforcement.. For UDL loads greater than 0.25kPa, custom Hebel Supercrete Panel will have to be designed to ensure structural adequacy when cut. Fig. 6.1 Hebel Supercrete panel being cut with portable saw with diamond blade
* or vertical distance between fastenings to Hebel Supercrete panel.
6.6 Custom Hebel Supercrete Panel

For Wall Types 2, 3 & 4, for heights exceeding 3000mm or design parameters outside the scope of this guide, the panels will be custom Hebel Supercrete Panel. These panels are designed to satisfy the projects design parameters, such as internal lateral (wind) pressure and on-site cutting requirements. Note that actual lateral design loads may limit the height of wall possible.
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6.7 Fastenings
All fastenings for deflection head channels, base angles, wall brackets and panels must be checked to ensure that the shear load applied by earthquake loads from the wall mass are within the capacity of the fastening. For Type 1 walls, where the Hebel Supercrete panels are exposed to external wind loads during construction, CFG Concrete Ltd recommends that the fastenings for securing angles and tracks to floor slabs be capable of withstanding a shear load of 0.75kN minimum. Depending on the structure size, site conditions and location, the designer may have to specifically design these for wind loads during construction. Minimum fastenings for Type 1 walls are shown in Table 6.2. Table 6.2 Fastenings for Wall Type 1 Location Bottom angle/track to structure Bottom angle to Hebel Supercrete Panel Track back-to-back Aluminium bracket to steel frame Aluminium bracket to Panels Fixing Type
6.8 Lightweight Support Framing

Typically Type 2, 3 & 4 walls are secured to concrete slabs and soffits. For walls that are secured at the head connection to lightweight support framing, such as structural steel roof framing, allowance must be made for vertical upward and downward movement. The magnitude of this movement could result in the standard head connections detailed in this Design Guide being inadequate. Contact your CFG Concrete Ltd representative to discuss the required head connection configuration.
Number of Fixings and Spacing 600mm max. centres 2 fixings per panel, 50mm min. from panel edge. 600mm max. centres 2 fixing per bracket 2 fixings per bracket
M8 bolt + 25 x 3mm load sharing washer 12-11 x 90mm hex head screws 10-16 x 16mm wafer head screws
Aluminium bracket to timber frame 12-11 x 25mm hex head screws 12-11 x 50mm hex head screws or 12-8 x 60mm button head screws
10-16 x 16mm hex head self-drilling screws 2 fixing per bracket
7.0 Design & Installation Considerations

Control Joints Control joints must be provided at a maximum of 6m spacing. Recommended control joint widths should be 10mm minimum between Hebel Supercrete Panel and another building component. Control joints must also be provided to coincide with any control joint in the main structure. The deflection head and base angle must be discontinuous at a structural control joint. These joints must use acoustic and fire rated sealants. Refer to Section 13.3 for control joint details. Wet Area Wall Construction Wet area wall construction requires a system that enables services to be installed in a cavity. Where back-to-back wet areas are to be installed, a Type 1 or Type 3 wall, which incorporate a cavity on both sides of the wall, is required. Penetrations Hebel Supercrete AWS walls can accommodate 300 x 300mm penetrations at 1200mm horizontal centres, without a reduction in structural performance. The edge of the penetration shall be 15mm maximum from the service passing through the wall. Contact your fire and acoustic consultants for detailing of penetrations to ensure the nominated fire and/or acoustic performance is achieved. Wall Chasing Panels should not be chased for services. 17 Acoustic & Fire Integrity Penetrations in walls for electrical fittings, telecommunications, large ductwork, or plumbing systems can be a substantial source of sound leakage, which can affect the acoustic and fire performance of the wall. When electrical, telecommunication or plumbing services are required, the contractor shall install these services neatly and, when passing through the wall, shall provide a close fitting hole, sealed with an approved fire and acoustic rated sealant. Detail of stopping material to be provided by appropriate consultant and installed in accordance with the manufacturers recommendations. To prevent water noise from degrading acoustic performance of the wall system, water-bearing pipes should be acoustically wrapped and resiliently fastened. CFG Concrete Ltd recommends the use of fire rated switch boxes and collars (such as those manufactured by CLIPSAL or HPM) as these assist in maintaining the acoustic integrity of wall systems. When installing these devices please consult with the manufacturer for design and installation recommendations. Electrical switches must not be installed back to back as this could be a source of sound leakage. Refer figure 7.1 for switch box layout guidance.
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Door Frames Door frames can either be built-in as the wall is being constructed or retrofitted after the Hebel Supercrete Panel has been installed. A typical door frame details have been included in Section 12.6. For further information and installation requirements, please contact your chosen door frame manufacturer. Fasteners The correct sized fasteners for the construction of the wall system must always be used. When fitting large or heavy
fixtures, guidance on the correct fasteners can be found in the Hebel Supercrete Fixing and Fastening Guide and/or fastener manufacturers recommendations. Fig 7.1 Switch Box Layout
600mm min.
8.0 System Components

WALL CoMPoNENTS WALL SYSTEM TYPE Type 1 75mm Hebel Supercrete Panel Head track Base angle Steel stud framing Timber stud framing Wall brackets Plasterboard Promaseal IBS rod Adhesive Mortar CSR Bradford insulation Fasteners/fixings Acoustic/fire sealants Corrosion protection paint
CFG Concrete Ltd recommends that the following components or equivalent be used. Table 3.1 Typical Hebel Supercrete AWS Wall Components Hebel Supercrete Panel Type 2 Type 3 Type 4 The primary component of Hebel Supercrete AWS walls is the 75mm thick Hebel Supercrete Panel. The panel is manufactured specifically for each job in a range of standard and custom sizes as indicated in Table 8.2. The standard panel is produced as a stock item, unlike the custom panel, which has to be manufactured and availability is subject to production lead times. Standard panels are manufactured with flat butt joints. Fig 8.1 Hebel Supercrete Panel Standard and T&G cross-sections
600mm 75mm Standard (Nil) Profile T&G Profile 600mm 75mm
Deflection Head Track For positioning and restraining the top of the panels the following deflection head tracks and angles are recommended for use in the AWS walls types 2, 3 and 4:
Note: Optional if in Detail 12.14 head track connection is specified. Rondo N498 galvanised deflection head track 76 x Use as required. Table 8.2 Standard and Custom 75mm Hebel Supercrete Panel Sizes 50 x 0.75mm base metal thickness (BMT); PANEL TYPE Standard LENGTH (mm) 1200 2400 2550 2700 2850 3000 Custom 3000 max 3200 Up to 3900 PANEL DIMENSIoNS WIDTH (mm) 300 600 WEIGHT (kg/m2) 49 49 49 49 49 49 49 49 53
76mm 50 or 35mm
Rondo J-Track Deflection Head 76 x 100 x 50 x 0.75mm BMT; or Galvanised steel angle 50 x 50 x 1.2mm BMT. For TP Head use: Slotted galvanised steel angle 75 x 50 x 1.2mm BMT.
Note: Average panel weight worked out at 30% moisture content. Double reinforcement
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Base Angle/Channel For positioning and restraining the bottom of the panels, the following base angles are recommended for use: Slotted galvanised steel angle 50 x 50 x 0.8mm BMT; Slotted galvanised steel angle 50 x 50 x 1.2mm BMT; or Punched base angle; Galvanized deflection head track Rondo No 498 76 x 50 x 0.75mm BMT, or Rondo No 402 76 x 35 x 0.75 BMT. All angles with BMT greater than 0.8mm will have to be slotted. Wall Brackets Wall brackets for Wall Type 1 are proprietary components nominally 75 x 40 x 1.6mm x 50mm wide. These can be aluminium, galvanized steel or zincalume.
There are number of different steel stud framework component manufacturers. All steel stud framework components are to be designed in accordance with manufacturers specifications, and AS/NZS 4600. Wall Type 1 may also be constructed using timber framing complying with NZS 3604. Insulation Hebel Supercrete AWS walls incorporate supplementary insulation materials. Tables 8.1 present basic information on glasswool insulation materials. Hebel Supercrete AWS wall systems that use glasswool insulation generally have a better acoustic performance than systems using Polyester insulation. CFG Concrete Ltd recommends the use of CSR Bradford Glasswool insulation. Additional information regarding Bradford insulation is available from www.bradfordinsulation. com.au Table 8.1. CSR Bradford Glasswool insulation
40mm
Glasswool Thickness 50mm 75mm

75mm
Mass g/m2 540 810 940 683
90mm
50mm
Wall bracket
105mm
Mortar Mortar is used to provide a level base for panel installation as well as providing acoustic and fire protection at the base of the panels. Mortar (supplied in 20kg bags) is used only as a mortar base, typically 10mm thick. Do not use for joints between panels. Adhesive Adhesive (supplied in 20kg bag) is used for bonding the panels together at vertical and horizontal joints. Joints should be 2-3mm thick. PromaSeal IBS Rod Promaseal IBS Rod (22mm) is a fire rated seal appropriate for 15mm maximum gaps and used on wall types 2, 3 & 4. It is positioned inside the deflection head track and compressed 7mm. Promaseal IBS Rod is available from PBS Distributors and Contracting Ltd, Auckland, or PBS South Island Ltd. Corrosion Protection Coating Reinforcement exposed when panels are cut shall be coated with a liberal application of Fentak Dipcoat or similar. Stud Framework Zinc coated steel studs, noggings, head and base tracks are used to create separated stud framework, which in conjunction with the Hebel Supercrete Panel, provides a cavity wall assembly for wall types 1, 2 or 3. 19 Plasterboard Hebel Supercrete AWS walls incorporate Plasterboard on both sides. The type, thickness and densities of plasterboard will be as per the specified wall requirements. Additional information is available from plasterboard manufacturers/ suppliers. Fasteners & Fixings Most screw fixings are timber type, which is sufficient for penetrating the metal thicknesses outlined in this Design Guide. Connections that have larger metal thicknesses may require a metal type screw and will need to be designed and approved by the project engineer. Fixings for Deflection Head Track and Base Angle to Concrete The fixing to secure the tracks to the concrete slab and soffits shall be capable of withstanding a shear load of 0.75kN. For high wind or earthquake loads the designer shall
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determine if mechanical fasteners are required. The following minimum fixings shall be provided: Drive pins and concrete nails (check size and suitability for fire rated situations with the manufacturer). 6mm diameter mechanical fasteners. For Wall Type 1, use M8 Dynabolts or similar with 25mm x 3mm load spreading washers. Hebel Supercrete Panel to Base Angle Fixings Use 14-10 x 65mm hex head screw or equivalent, when fixing through the track into the panel. (See Figure 8.1). Angles with BMT greater than 0.8mm will have to be slotted. Fig 8.1 14-10 x 65mm hex head
Use 10 x 16 x 16mm self drilling hexagon head screws into steel frames. Use 12-11 x 50mm hexagon head screws to fasten brackets to Hebel Supercrete Panel. Fig 8.2 12-11 x 50mm hex head screw
Plasterboard to Hebel Supercrete Panel Fixings 50mm bugle head coarse thread screw or equivalent. (See figure 8.3). Fig 8.3 50mm bugle head coarse thread screw
Use 14-10 x 90mm MP Bugle Head screw or equivalent, when fixing through the panel and into the track. For angles with BMT greater than 0.8mm, the screw will require the appropriate tip. Back to Back Track Fixings For joining steel channels for panel joints in Wall Type 1 (option 2 Detail use 10-16 x 16 mm self drilling wafer head screws. These must be used with the tracks sitting in place on the lower panel so the screw enters the lower panel. Wall Brackets for Wall Type 1 Use 12-11 x 25mm hexagon head screws into timber frames.
Door Frames to Hebel Supercrete Panel Fixings 50mm coarse thread screw or equivalent. Check screw requirements with door manufacturers specifications. Screws for panel returns Use 14-10 x 150mm (100mm thread) hex head screw or equivalent. Fire & Acoustic Sealant To attain the specified FRR and/or STC requirements, all perimeter gaps and penetrations must be carefully and completely filled with an appropriate flexible polyurethane sealant installed to manufacturers specifications.
9.0 Installation of AWS Walls

Setting Out and Positioning of Walls Before commencing any installation work, clean and tidy up the work area. Mark out the location of the walls and door nibs, etc. Deflection Head Track and Base Angle Installation When the wall locations have been set out fix the deflection head tracks and base angles to the concrete support structures. This is done using suitable fixings (see Section 8) at 600mm maximum centres and maximum 100mm from ends. At changes in wall directions, ensure deflection head track is mitred with no gaps at the corners. Seal all butt joints with polyurethane sealant. Use a laser or plumb line to ensure vertical alignment. Gaps between the deflection head track and irregular soffit surfaces should be sealed with a 5mm minimum diameter bead of sealant as per project specifications. Promaseal IBS Rod Installation Promaseal IBS Rod or equivalent is positioned inside the deflection head track. Tape or contact adhesive may be used to temporary secure the rod in place prior to installation of the panel. Select the appropriate diameter rod to suit the deflection gap at the top of the wall. For a 15mm gap adopt a 22mm diameter Promaseal IBS Rod. The rod should be continuous through connections and the rod shall be spliced by overlapping a minimum of 200mm. Mortar Installation Mortar is placed after the base angle is installed, it should only be run out a maximum of 3 panels (1800mm) ahead of panel installation. The mortar bed fills the gap at the base as the IBS rod is compressed by the panels. Generally, the mortar is 10mm thick and shall extend the full width of the panel. Care must be taken not to drag mortar to the angle upstand, causing panel misalignment. Mixing of the mortar should be done in accordance with the instructions on the bag.
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Hebel Supercrete Panel Installation The panels can be cut on-site using a circular saw equipped with diamond tipped cutting blade (for panel cutting limitations refer to Section 6.3). All the loose AAC particles should be brushed off the panel with a rough broom. Steel reinforcement that is exposed during cutting must be coated with a liberal application of corrosion protection coating (see Section 8). Any minor damage and chips to the panels must be repaired with Adhesive mixed with AAC dust or High Build Render. As the panel is positioned into place the rod must be compressed the specified minimum distance. A 22mm diameter Promaseal IBS Rod shall be used in a 15mm gap and shall be compressed 7mm minimum. No fixings should be used to compress the rod. Use packers at the base to maintain the gap at the top. Ensure base gap is full of mortar. Fix the panel to the base angle with a minimum of 2 screws (see Section 8), 50mm minimum from each end of the panel. For subsequent panels, apply Adhesive to the vertical edge and install next panel. Repeat the installation process until the wall is complete. For Wall Type 1, wall brackets should be fastened first to stud wall and then to each panel as it is placed. Wall brackets to the second stud wall are fastened after the second stud wall is framed. Adhesive Application Adhesive is applied to the panel with a 75mm Hebel notched trowel. When the panels are pushed together the joints are to be 2-3mm thick. Sufficient pressure must be applied to the panels when gluing to ensure the adhesive is fully bedded across the joint. Scrape off any excess adhesive protruding from the joints and fill any gaps. Adhesive is to be mixed to the proportions and consistency as per the instructions on the bag. Stud Framework Installation For Wall Type 1, timber or steel stud framework on one side of the Hebel Supercrete Panel is erected before the panel is placed. For all other wall types, wall framing is installed after the panels. All steel stud framework is to be installed to the manufacturers specifications. Installation of Insulation Installation of insulation should be completed in accordance with manufacturers handling and installation guidelines. The
thickness of insulation provided should be such as to fully fill the face of the cavity. If there is any gap in the insulation, the acoustic performance of the system may be adversely affected. Plasterboard Plasterboard sheets must be cut to fit neatly and should not be forced into position. The plasterboard is to extend the full height of the wall with gaps at top and bottom for the specified sealant. In Hebel Supercrete AWS walls, plasterboard is fixed directly to Hebel Supercrete Panel or stud framework. Direct fix to Hebel Supercrete: Plasterboard is to be installed in accordance with the plasterboard manufacturers installation guidelines and secured in position with the appropriate screws (see Section 8.0). Stud Side: Plasterboard is to be installed in accordance with the manufacturers recommendations for steel frame or timber frames wall systems. Installation of Sealants All movement joints and other gaps should be sealed off and finished neatly with fire and acoustic rated sealants. Installation of sealants must be carried out in accordance with the manufacturers specifications. Installation of Penetrations, Electrical, Plumbing and Other Services Installation of services and penetrations into Hebel Supercrete AWS walls should be carried out in an appropriate construction sequence. This will allow easy access to cavities, steel framed elements and panels, where services can be easily installed and neatly hidden. CFG Concrete Ltd suggests installing the plumbing and cabling after the panels have been installed. The builder or project manager should confirm appropriate construction sequence for services and penetrations on a project-byproject basis. Neat finishes for all penetrations is necessary to maintain the acoustic and fire integrity of the wall. For more information regarding installation of services and penetrations refer to Sections 7 & 12.7 of this Design Guide. Installation of Fasteners & Fixings All fixings and fasteners should be installed in accordance with the manufacturers specifications.
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10.0 Panel Handling

Manual Handling CFG Concrete Ltd recommends using a trolley or other mechanical apparatus to move the panels around the work site. Manual handling where people physically move a panel, should be kept to a minimum, with the weight being supported by an individual kept as small as possible. Any concerns regarding the weight to be handled should be discussed with the panel installation contractor. To minimise the possibility of manual handling injuries, CFG Concrete Ltd suggests the following: Use mechanical aids, such as trolleys, forklifts, cranes and levers, or team lifting to move panels. Keep the work place clean to reduce the risk of slips, trips and falls, which can cause injury. Plan the sequence of installation to minimise panel movements and avoid awkward lifts. Train employees in good lifting techniques to minimise the risk of injury. Health and Safety Hebel Supercrete products are cementbased, which may irritate the skin, resulting in itching and occasionally a red rash. The wearing of gloves and suitable clothing to reduce abrasion and irritation of the skin is recommended when handling Hebel Supercrete products. Approved respirators (AS/NZS1715 and AS/NZ1716) and eye protection (AS1336) should be worn at all times when cutting. Refer to the Hebel Supercrete Material Safety Data Sheets. The use of power tools when cutting any concrete products causes dust, which contains respirable crystalline silica, with the potential to cause bronchitis, silicosis and lung cancer after repeated and prolonged exposure. When using power or hand tools, on Hebel Supercrete products, wear a P1 or P2 respirator and eye protection. When cutting, routing or chasing Hebel Supercrete products with power tools, use dust extraction equipment and wear hearing protection. Refer to the back page of this Design Guide for further information regarding health and safety.
Fig 10.1 Positioning a panel onto the trolley
Fig 10.2 Tipping the trolley onto its wheels Fig 10.4 Personal Protection Equipment used when handling/cutting panels.
Dust Mask
Safety Goggles Fig 10.3 Transporting a panel to the wall

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11.0 Delivery & Storage

Unloading Panels Panels shall be unloaded and moved with only approved lifting devices. Before use, the lifting devices should be checked for the required lifting tags. Panels should be unloaded as close as possible to the intended installation area. This will increase work efficiency and minimise the need for secondary lifting. Note: Secondary handling increases the risk of panel damage. The repair of damage sustained during lifting and moving is the responsibility of the lifter. Where damage is excessive, panels must be replaced. Storage All materials must be kept dry and preferably stored undercover. Care should be taken to avoid sagging or damage to ends, edges and surfaces. All Hebel Supercrete products must be stacked on edge and properly supported off the ground, on a level platform. Panel bundles can be stacked two high for ease of access on site. The project engineer should be consulted as to the adequacy of the structure to support the stacked bundles. Each bundle contains 10 panels. Where bundles are stacked two high, the supporting cleats must be vertically aligned, to ensure minimal bending of the lower panels. Refer to Figure 11.2. Where panels are being used in multi storey applications, the capacity of the floor to support the concentrated load of panel pallets must be checked prior to lifting on to the floor. If Hebel Supercrete Panel is stored outside, it must be stored off the ground and protected from the weather. Only single bundles positioned on the ground can be opened. To provide a level surface, we recommend placing temporary joists beneath the supporting cleats. 23
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Fig 11.1 Hebel Supercrete 75mm Panel Shipping Bundle
Metal strapping
Support pallet Plastic shrink wrap cover Handing Guidelines
Fig 11.2 Stacking Bundles of Hebel Supercrete Panels

Panel Length Strapping Panel Width Panel Thickness
Panel Width
Temporary joists may be required on uneven ground
Fig 11.3 Panels awaiting shipping at Somersby factory
Plasterboard to system specification
12.0 AWS Construction Details

12.1 Hebel Supercrete Panel Construction Details
Supercrete Panel Detail 12.1.1. Wall Type 1 Base Connection option 1 Continuous Mortar Damp proof course Continuous Mortar Damp proof course Aluminiumto system Insulation bracket fixed to frame with toxsystemx Plasterboard specification 2 2mm 25mm gal nails or 2 x specification 12-11 xHebel hex head 75mm or steel Timber 50mm screws for timber Supercreteper project framing as Panel framing, or 2 x 10-16 x specifications 16mm wafer head fixed Aluminium bracket screws for steel x 2mm x to frame with 2 framing 10-20mm gap 25mm gal nails or 2 x 12-11 x 50mm hex head Insulation timber screws forto system specification framing, or 2 x 10-16 x 16mm wafer head screwsHebel 75mm for steel framing Supercrete Panel Aluminium bracket fixed to frame with 2 x 2mm x 25mm gal nails or 2 x 12-11 x 50mm hex head screws for timber framing, or 2 x 10-16 x 16mm wafer head screws for steel framing NOTE: This frame to be constructed first Plasterboard to system 75mm Hebel 10-20mm gap Timber or steel Insulation to system framing as per project specification specifications Plasterboard 10-20mm gapto system specification
Timber or steel framing as per project specifications
Detail 12.1.4. Wall Type 1 Horizontal Joint Fixing option 1

Bracket fixed to frame with 2 x 2mm x 25mm gal nails or 2 x 12-11 x 25mm hex head type 17 screws for timber framing, or 2 x 10-16 x 16mm wafer head screws for steel framing Fibre Cement packer or non-combustible equivalent
Continuous Mortar Damp proof course
Backing rod and fire and acoustic rated sealant to project specifications Bracket fixed to Hebel Supercrete Panel with 2 x N12-11 x 50mm hex head screws, or 2 x N12-8 x 60mm button head screws
Detail 12.1.2. Wall Type 1 Base Connection option 2 specification

Timber or steel NOTE: This frame to be framing as per project constructed first specifications 75mm Hebel Supercrete Panel 10-20mm gap to system Plasterboard specification Insulation to system Timber or steel specification project framing as per specifications Hebel Supercrete Panel 10-20mm gap fixed to This frame to be NOTE: continuous steel angle with 14-10 x constructed first Insulation head screws 95mm hex to system specification at 600mm max. ctrs Plasterboard to system
Detail 12.1.5. Horizontal Joint Fixing option 2
75mm Hebel Continuous Supercrete Mortar Panel Damp proof course Continuous Mortar Damp proof 75mm Hebel course Supercrete Panel
Fixed back to back with 10-16 x 16mm wafer head screws at 600mm max. centres Continuous steel channel 76 x 32 x 0.75mm BMT OR 76 x 50 x 0.75mm Deflection Track or J-track
150mm min.
specification Continuous steel angle Hebel Supercrete Panel fixed to slab with Timber or steel fixed to continuous steel masonry as per project framing anchors at angle with 14-10 x 600mm max. ctrs specifications 95mm hex head screws at 600mm gap ctrs 10-20mm max. Continuous steel angle Insulation to system fixed to slab with specification masonry anchors at 600mm max. ctrs Hebel Supercrete Panel fixed to continuous steel angle with 14-10 x 95mm hex head screws at 600mm max. ctrs
150mm min.
16mm Gib Fyreline Plasterboard or similar fixed to Hebel Supercrete Panel with 10 x 50mm bugle head laminating screws at 400mm centres max.
Continuous Mortar
Detail 12.1.6. Bracket Fixing
Detail 12.1.3. Wall Type 1 Base Connection option 3 Damp proof Continuous steel angle
course fixed to slab with masonry anchors at 600mm max. system Plasterboard toctrs specification Centreline of panel 600mm wide Hebel Supercrete Panel (one panel)
Timber or steel framing as per project specifications Plasterboard 10-20mm gapto system specification Timber or steel Insulation to system framing as per project specification specifications 10-20mm gap Plasterboard to system Insulation to system specification specification Continuous steel channel (Rondo 76 x Timber or steel 32 x 0.75mm) fixed framing as per project with masonry anchors specifications at 600mm max. ctrs 10-20mm gap Continuous steel channel (Rondo 76 x 32 x 0.75mm) fixed Insulation to system with masonry anchors specification at 600mm max. ctrs
75mm Hebel Supercrete Panel
Wall bracket shall be fixed to panel within a 100mm wide central region of the panel
50mm 50mm
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18.2.1to be read in conjuction with the current Hebel Supercrete Acoustic Wall Systems Design Guide, AWS 2009 Details Deflection Head
Detail 12.1.7. Deflection Head Top Track. Use where H 3200mm for Wall Types 2, 3 & 4
Deflection head fixed to soffit Concrete soffit 15mm max. 50mm 35mm
Detail 12.1.8. J-Track Top Track. Use where H 18.2.2 j 2, 3 & 3200mm for Wall Types Track4
22mm IBS rod Concrete soffit 15mm max. 75mm 35mm J-track fixed to soffit
22mm IBS rod
Detail 12.1.9. Top Track. H 3200mm for Wall Types 2, 3 & 4

22mm IBS rod Fix angle to soffit slab
Detail 12.1.10.Top Track. Use where H 3000mm for 3000mm for Wall Types 2, 3 & 4
Backing rod Fix angle to soffit slab
15mm max. 35mm

15mm max.
Galvanised Steel Angle 50 x 50 x 1.2mm
30mm
Acoustic and fire rated sealant
Slotted steel angle 75 x 50 x 1.2mm
18.2.6 Sealing _ New Illo Supercrete

Panel
75mm Hebel
18.2.6 Base angle
Detail 12.1.11. Sealing of gaps between Top Track and Slab Soffits for Wall Types 2, 3 & 4
Deflection head fixed to soffit Concrete soffit
Detail 12.1.12. Base Angle
Apply sealant after installation of Deflection Head
Option 1
Deflection head fixed to soffit Concrete soffit Fire and acoustic rated sealant
75mm Hebel Supercrete Panel Mortar as required Concrete slab
14-10 x 65mm hex head screw Rondo steel angle 50 x 50 x 0.8mm (H<3200) or Rondo steel angle 50 x 50 x 1.2mm (H>3200mm)
Deflection Head bedded in sealant during installation
Rondo base angle fixed to slab
Option 2
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Details to be read in conjuction with the current Hebel Supercrete Acoustic Wall Systems Design Guide, AWS 2009 18.2.6 Vertical Edge
Detail 12.1.13 Vertical Edge Square Edge Panels

Adhesive between panels
Detail 12.1.14 Panel To Column Junction. Use where H 3100mm and/or panel width 300mm
Masonry/concrete wall or column 10mm min. Fire and acoustic rated sealant
Non fire rated foam backing rod 75mm Hebel Supercrete Panel Fire and acoustic rated sealant 75mm Hebel Supercrete Panel
18.2.7 Vertical Edge

Detail 12.1.15 Vertical Edge T&G Profile Panels
Detail 12.1.16 Panel to Column High Wall Junction. Use where H 3100mm and/or panel width 300mm
Masonry/concrete wall or column 75mm Hebel Supercrete Panel Fire and acoustic rated sealant
22mm IBS rod
Rondo 75 x 50 x 0.75 min. head fixed to project specifications 15mm max.
Detail 12.1.17 Corner Junction
14-10 x 150mm hex head coarse thread screw at 900mm max. centres and 100mm max. from panel end (3 per panel min.)
Detail 12.2.18 Splay Corner Junction
14-10 x 150mm hex head coarse thread screw at 900mm max. centres and 100mm max. from panel ends (3 per panel min.)
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12.2 Junction Details

Detail 12.2.1: External Wall Junction for Wall Type 1
UNIT 1
Optional insulation
75mm Hebel Supercrete Panel external wall system as per project specification
Bradford Fibertex 450 Rockwool wedged between studs. Use 75mm thickness for 70mm frame, or 2 x 50mm thicknesses for 90mm frame. Bradford Fibertex 450 Rockwool to 300mm min. each side of intertenancy wall
Plasterboard to system specification
Wall Brackets
10-20mm gap
EXTERNAL
IMPORTANT: Provide a control joint at junction of the external wall and the Hebel Supercrete intertenancy wall Mineral fibre or other fire-resisting material as per project specifications for fire and acoustic purposes (nominal density 60kg/m3) Building wrap Rondo 303 battens
Bradford insulation as per project
Timber or steel framing as per project specifications Hebel Supercrete intertenancy wall Plasterboard to project specifications
UNIT 2
Optional insulation
Detail 12.2.2: External Wall Corner Junction for Wall Type 1

75mm Hebel Supercrete Panel intertenancy wall Wall brackets Plasterboard to system specification Mineral fibre or other fire-resisting material as per project specifications for fire and acoustic purposes (nominal density 60kg/m3)
Bradford or similar insulation as per project specifications 10-20mm gap Plasterboard to system specification
UNIT 2
Bradford Fibertex 450 Rockwool to 300mm min. each side of party wall Optional insulation
UNIT 1
Bradford Fibertex 450 Rockwool to 300mm min. each side of intertenancy wall IMPORTANT: Provide a control joint at junction of the external wall and Hebel Supercrete intertenancy wall Building wrap 75mm Hebel Supercrete Panel external wall as per project specification
EXTERNAL
Optional insulation 75mm Hebel Supercrete Panel external wall as per project specification NOTE: Fixings not shown for clarity
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Detail 12.2.3 Corner Junction Type 2 Wall

14-10 x 150mm hex head coarse thread screw at 900mm max. centres and 100mm max. from panel ends (3 per panel min.) Fire and acoustic rated sealant Hebel between panels
Detail 12.2.4 Wall to Column Junction Type 2 Wall for H 3100mm

Insulation as per system requirements 10mm fire and acoustic rated sealant Steel stud as per system requirements Masonry or concrete wall or column Plasterboard as per system requirements
Detail 12.2.5 Walls to Column Junction Type 2 Wall for H 3100mm

Insulation as per system requirements Steel stud as per system requirements Masonry or concrete wall or column Plasterboard as per system requirements Non fire rated backing rod and fire rated sealant
Plasterboard as per system requirements 10mm fire and acoustic rated sealant
Detail 12.2.6 Type 2 Wall Junction

Hebel Supercrete AWS or Corridor Intertenancy Wall System Unit 1 Hebel Supercrete AWS Wall System
Plasterboard as per system requirements Rondo 18.3.9 75 pp deflection head fixed to project specifications Fire and acoustic rated sealant
Detail 12.2.7 Type 4 Wall to External Wall Junction

150mm Coating system to project specifications CIWS Hebel Supercrete Panel 6mm x 300mm long stainless steel dowels (3 per panel min.) Backing rod and sealant to project specification Internal wall system to project specifications
Non fire rated foam backing rod Corridor or Unit 3 Unit 2
Non-fire rated backing rod, and fire and acoustic rated sealant to project specification
Detail 12.2.8 Type 4 Wall to External Wall Junction Section AA on Detail 12.2.5
Fire and acoustic rated sealant between damp proof course and panel Hebel Supercrete Panel Damp proof course to project specifications Non fire rated backing rod, and fire and acoustic rated sealant to project specifications
Vertical damp proof course full height of wall EXTERNAL SIDE
Type 4 Wall Fire and acoustic rated sealant between damp proof course and external panels
Coating system to project specifications Panel bedded in Mortar
Hebel Supercrete Type 4 AWS wall system Panel bedded in Mortar
Detail 12.2.9 Type 2 Wall to Internal Wall Junction

Hebel Supercrete Internal Wall System or other Partition Wall Systems Unit 2
Sealant to project specifications Waterproof membrane to project specifications Cement render to project specifications
Structural concrete nib to project specification Concrete slab
Hebel Supercrete Internal Wall System or other Partition Wall Systems Unit 1
Refer to project acoustic consultant for appropriate acoustic treatment of cavity area
Hebel Supercrete AWS Intertenancy Wall System
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12.3 Roof Details

Detail 12.3.1 Roof Valley for Wall Type 1
Mineral fibre or other fire-resisting material as per project specifications for fire and acoustic purposes (nominal density 60kg/m3)
Bradford or similar insulation as per project specifications
Bradford or similar insulation as per project specifications
Blocking 45mm thick between trusses as required Wall brackets each side of panel Timber framing as per project specification 75mm Hebel Supercrete Panel 20-25mm gap Bradford or similar insulation as per project specifications
Detail 12.3.2 Roof Parapet for Wall Type 1
Mineral fibre or other fire-resisting material as per project specifications for fire and acoustic purposes (nominal density 60kg/m3)
Wall brackets each side of panel Max.1200mm between top hats
Blocking 45mm thick between trusses as required Wall brackets each side of panel Timber framing as per project specifications 75mm Hebel Supercrete Panel 20-25mm gap Bradford or similar insulation or similar as per project specification
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12.4 Control Joint (C.J.) Details

Detail 12.4.1 Type 2 and 3 Walls Fire Rated C.J.

Fire and acoustic rated sealant 15mm max. Backing rod non fire rated 22mm dia.
Plasterboard as per system specification
Tracks to be discontinuous at control joint Additional stud to form control joint Stud in normal position 75mm Hebel Supercrete Panel
Plasterboard as per system specification
Backing rod non fire rated 22mm dia. 10mm RONDO P35 Control Joint with set finish
NOTES: For double layer lining systems, the minimum depth of approved fire and acoustic rated sealant shall be 20mm.
12.5 Wet Area Wall Details

Detail 12.5.1 Shower Area
Detail 12.5.2 Bath Area

Required system wall linings
75mm Hebel Supercrete Panel 1 or 2 layers of moisture resistant plasterboard as per system requirements Vertical corner angle flashing Ceramic tiles Insitu internal membrane applied to face of wall lining and floor Flexible sealant Masking tape Foam plastic rod used as essential bond breaker Mortar bed Continuously fill gap with required sealant Approved flashing when required by buildingregulations
Steel Studs and insulation as per system requirements 1 or 2 layers of moisture resistant plasterboard as per system requirements Vertical corner angle flashing Ceramic tiles Insitu internal membrane applied to face of wall lining and floor Flexible sealant Masking tape Foam plastic rod used as essential bond breaker Mortar bed
75mm Hebel Supercrete Panel 1 or 2 layers of moisture resistant plasterboard as per system requirements
Steel Studs and insulation as per system requirements 1 or 2 layers of moisture resistant plasterboard as per system requirements
Ceramic tiles Flexible sealant 6mm
Ceramic tiles Flexible sealant 6mm
Bath
Bath
Support batten fixed to framing Mortar bed
Support batten fixed to framing Mortar bed Continuously fill gap with required sealant
Concrete slab
Continuously fill gap with required sealant
Continuously fill gap with required sealant
Concrete Slab
AWS 2009
30
12.6 Door Details

Detail 12.5.1 Door opening Type 1
Detail 12.6.2 Door opening Type 2

NOTE: Lintel must be fully glued to adjacent panels.
Lintel ( Hebel Supercrete Panel)
Rondo deflection head powerfixed to slab
14-10 x 150mm hex head coarse thread screws
Lintel ( Hebel Supercrete Panel)
Fully glue lintel panel to adjacent panels
Rondo deflection head powerfixed to slab
100mm min. Door opening
100mm min.
Door opening
Base angle powerfixed to slab
300mm min.
Base angle powerfixed to slab
Detail 12.6.3 E-Core Fire Door or similar for Type 2 Wall Systems
NOTE: All gaps between wall and frame to be filled with Hilti CP 611A intumescent firestop mastic or equivalent. Fire and acoustic rated sealant to manufacturer's recommendations Steel frame or furring channel to manufacturer's specifications Plasterboard as per system requirements
Detail 12.6.4 Door Nib

75mm Hebel Supercrete Panel 14-10 x 150mm hex head coarse thread screw at 900mm max. centres and 100mm max. from panel ends (3 per panel min.)
136 171mm
Fire rated metal door frame (fill as specified)

Fire rated metal door frame (fill as specified) Door frame to manufacturers specifications
Rivets at 300 to 400mm centres Retaining strip
65mm hex head screws to door manufacturer's specifications 50mm bugle head coarse thread screws at 300 to 450mm centres
270mm min Plasterboard as per system requirements
Detail 12.6.5 E-Core Fire Door or similar for Type 4 Wall Systems
Retaining strip 1.4m thick Laminated 50mm bugle head coarse thread screws at 300 to 450mm centres NOTE: All gaps between wall and frame to be filled with Hilti CP 611A Intumescent firestop mastic or equivalent. Rivets at 300 to 400mm centres 75mm Hebel Supercrete Panel
Important:
1. All door frame installations and detailing to be approved by door frame manufacturer. 2. Continuously screw fix door frame to Hebel Supercrete Panel around perimeter of door opening. 3. CFG Concrete Ltd recommends core filling of the door frame for additional robustness.
Unfilled
75mm Hebel Supercrete Panel E-Core Fire door or equivalent Insulation Plasterboard 4mm dia. holes with 14-10 x 65mm hex head screws at 300 to 450mm centres
4. Fix door frame at the base.
31
AWS 2009
12.7 Penetration and Services Details

Detail 12.7.1 Large Penetration in Wall

Rondo deflection head powerfixed to slab Lintel (Hebel Supercrete Panel) Full height vertical panel
Detail 12.7.2 Power Switch Installation into Hebel Supercrete Panel

15mm max. Switch mounting plate Electric switch Insulation as per system requirements Plasterboard as per system requirements Fill penetration with fire and acoustic rated sealant Neat cable penetration 75mm Hebel Supercrete Panel
100mm min.
Opening 900 x 400mm 100mm min.
Horizontal panels
14-10 x 150mm hex head coarse threaded screw
Neat rebate for switch 50mm bugle head coarse thread screw
Detail 12.7.3 Power Switch Installation into Cavity

Insulation as per system requirements Plasterboard as per system requirements Plasterboard as per system requirements Fire rated switch box
Detail 12.7.4 Metal Pipe Penetration

Provide 400 x 400mm backblock fixed with laminating screws in single layer lining systems Fire and acoustic rated sealant to manufacturer's specifications Cover plate Plasterboard as per system requirements
Seal cable penetration as per switch box manufacturer's requirements 75mm Hebel Supercrete Panel
Fire and acoustic rated sealant Electrical cables run in cavity
Metal pipe
15mm max. Non fire rated backing rod Neat penetration Insulation as per system requirements 75mm Hebel Supercrete Panel
Detail 12.7.5 Fire Collar Penetration

NOTE: Appropriate project consultant to approve installation detail to satisfy projects acoustic and fire performance requirements. Plasterboard as per system requirements Fire collar as determined by appropriate consultant Secure fire collar to panel as per the fire collar manufacturer's specifications Plastic Pipe
Fire rated backing rod and appropriate sealant to fire collar manufacturer's specifications 75mm Hebel Supercrete Panel
Non fire rated backing rod and fire rated sealant to fire collar manufacturer's specifications Insulation as per system requirements
AWS 2009
32
Appendix A
A1 Hebel Supercrete Panel Material Properties
Hebel Supercrete Panel Physical Properties 1) Nominal dimensions and profiles of standard and custom 75mm Hebel Supercrete Panel are shown in Section 8. 2) Standard 75mm Hebel Supercrete Panel has a single layer of steel reinforcement consisting of 4 longitudinal bars of 5mm diameter. 3) Custom 75mm Hebel Supercrete Panel has a single or double layer of steel reinforcement consisting of 4 or 5 longitudinal bars of 5mm diameter. 4) Nominal dry density = 510kg/m3. 5) Average working density = 663kg/m3 at 30% moisture content. 6) Average service life density = 561kg/m3 at 10% moisture content. 7) For custom Hebel Supercrete Panel average working density =707kg/m3 at 30% moisture content. Hebel Supercrete Panel Strength Properties 1) Characteristic compressive strength, f m = 2.8 MPa. 2) Average compressive strength = 3.2 MPa. 3) Characteristic Modulus of Rupture, f ut = 0.60 MPa. Hebel Supercrete Panel Fire Rating Properties For FRR ratings of Hebel Supercrete 75mm Panel and AWS walls refer to fire opinions FCO-2073, FCO-2327 and WFRA 45771.3. Hebel Supercrete Panel Acoustic Properties 75mm Hebel Supercrete Panel with no plasterboard or other lining has an STC = 37dB (refer to ATF-676 test and PKA-201006 opinion). Hebel Supercrete Panel Thermal Properties R-Value of bare 75mm Hebel Supercrete Panel with no plasterboard or other lining = 0.43 m2K/W at 10% moisture content. Typical Thermal Calculations
Wall Type 1 Indoor air film 10mm Plasterboard Insulation Air space 75mm Hebel Supercrete Panel Air space Insulation 10mm Plasterboard Indoor air film Total R Wall Type 2 Indoor air film 10mm Plasterboard 75mm Hebel Supercrete Panel Insulation 10mm Plasterboard Indoor air film
R 0.12 0.059 2.2 0.14 0.43 0.14 2.2 0.059 0.12 = 5.468 R 0.12 0.059 0.43 2.2 0.059 0.12
33
AWS 2009
A2 Proforma Architectural Specification

This specification should be adopted as a guide only, and shall be superseded by the contract specifications of the project. * Insert or select appropriate specifications. Scope The contractor shall furnish all material and equipment required to satisfactorily complete the installation and jointing of the Hebel Supercrete Acoustic Wall System nonloadbearing wall where indicated in the contract specification and/or on the layout drawings. Materials All AAC material shall be 75mm Hebel Supercrete Panel as manufactured by CSR Hebel. All accompanying fixings shall be as per the current Hebel Supercrete Acoustic Wall Systems Design Guide, AWS 2009 and/or the appropriate project consultants specifications. All lining materials shall be plasterboard manufactured to meet the dimensional requirements of AS/NZS2588 Gypsum Plasterboard. Steel frame components shall be those manufactured by Rondo Building Services Pty Ltd (or products of equivalent or better performance). Levels of Finish All framing, plasterboard lining, jointing and finishing shall be carried out to *Level Level of Finish, in accordance with AS/NZS2589.1 Gypsum Linings in Residential and Light Commercial Construction Application and Finishing. Wall System The contractor shall supply and install Hebel Supercrete Panel and Acoustic Wall System non-loadbearing wall (tablesystem-wall type) *()-()-(), in accordance with the current Hebel Supercrete Acoustic Wall Systems Design Guide, AWS 2009, and shall satisfy the following performance criteria. The wall shall have a Fire Resistance Rating *// in accordance with the requirements of AS/NZ1530.4. Installation shall be carried out to the level specified for a field acoustic performance of *STCusing cavity infill of fibreglass batts or equivalent. Wall Framing Wall framing shall consist of lipped steel studs *xxmm BMT installed at *mm maximum centres into steel floor and ceiling
AWS 2009
track *xxmm BMT. The gap between the Hebel Supercrete Panel and the framing shall be *mm (10mm minimum NOTE: It is important that the project engineer approve the type, size and maximum spacing of the fasteners to meet the design load requirements. Plasterboard Caution: Fire rated installations must be fastener fixed. Adhesive is not permitted. Adhesive does not constitute a fixing system by itself. Adhesive daubs must never coincide with fastening points. Stud adhesive MUST NOT be used on FIRE RATED or TILED WET AREA systems. The Hebel Supercrete Panel wall/steel framing/timber framing shall be lined on the first side with one layer of *mm * plasterboard. (followed by a second layer of *mm * plasterboard.) The Hebel Supercrete Panel wall/steel/timber framing shall be lined on the second side with one layer of * mm * plasterboard. (followed by a second layer of *mm * plasterboard.) Plasterboard Fixing All layers shall be fixed to the Hebel Supercrete Panel as specified for the relevant system, in the current Hebel Supercrete Acoustic Wall Systems Design Guide, AWS 2009. All layers shall be fixed to the steel framing or timber framing as specified for the relevant system in the Plasterboard Manufacturers Installation Guide, Technical Literature, and Rondo Building Services Pty Ltd literature or steel frame manufacturers literature. Caulking *fire rated polyurethane sealant / Promaseal IBS Rod + *acoustic rated polyurethane sealant must be used in fire rated systems where caulking is indicated, and installed in accordance with the manufacturers recommendations. *polyurethane sealant must be used when caulking * non-fire rated/fire rated wet areas, as indicated, and installed in accordance with the manufacturers recommendations. Important Any variation or substitution of materials or assembly requirements, or compromise in assembly may result in failure under critical conditions. 34
A3 Installation Checklist
Checklist to be read in conjunction with ALL Hebel Supercrete documentation including the Hebel Supercrete Technical Manual and the current Hebel Supercrete Acoustic Wall Systems Design Guide AWS 2009 and technical advice from CFG Concrete Ltd. Co-ordination and compliance with project consultants specification is compulsory. BUILDING: ______________________________________________________________________________________________________ LEVEL: _______________________________________ GRID OR AREA: __________________________________________________
INSTALLATION TASK/ITEM SATISFACTORy ACTION REqUIRED (see notes)
1. Has the specified ______________ mm head track been installed in accordance with project specifications? All gaps should be filled between the head track and concrete soffit with a fire and acoustic rated sealant. The deflection head should be overlapped where necessary. Ideally a continuous length of track should be used at the top of the panels. 2. Has the correct diameter IBS rod been used for the specified deflection gap? For a 15mm deflection gap, has a 22mm diameter Promaseal IBS been installed? The rod is not to be compressed by any fixing. Ideally the rod should be continuous, where the rod has to be spliced the rod shall be overlapped a minimum of 200mm. Has the IBS rod been overlapped 200mm minimum at splices/joins? At the ends of walls, where panels abut concrete walls/columns, the IBS rod shall turn down a minimum of 400mm? Has the IBS rod been turned down 400mm minimum at the end of the wall? 3. Has the specified ______________ mm base track been installed in accordance with project specifications? 4. Panel Installation Has Hebel Supercrete Panel been installed? Has the Promaseal IBS rod been compressed the amount specified by the manufacturer? 7mm compression for the 22mm diameter IBS rod. Has Mortar been installed at the base of the panel? Has the panel been secured to the base track with a minimum of 14 10 x 65mm Hex Head screws (locate a minimum of 50mm from either end)? 5. Are the vertical joints glued with Adhesive? Is the joint width 2-3mm? 5a. Rigid Corner Joints Have, 14 10 x 150mm Hex Head screws or approved equivalent and Adhesive been used in accordance with Hebel Supercrete Acoustic Wall Systems Design Guide to form returns? Have the screws been located at 100mm minimum from either end of the panels and at 900mm maximum centres? 5b. Control Joints Install control joints at a maximum of 6m spacing to internal walls, a 10mm minimum allowance to be made for a foam backer rod and fire rated sealant or Promaseal IBS rod and acoustic sealant where applicable. Has a control joint been installed where the Hebel Supercrete panels abut concrete columns or walls? Has the specified foam backing rod and sealant been placed in the control joint? 5c. Damaged Panels Did Hebel Supercrete representative acknowledge that damaged panels were acceptable for repair? 5d. Cut Reinforcement Has the cut reinforcement been coated with the corrosion protection paint in accordance with Hebel Supercrete Acoustic Wall Systems Design Guide? 6. Have door jambs been installed (supplied by others) in accordance with the door manufacturers recommendations and Hebel Supercrete Acoustic Wall Systems Design Guide? 7. Has the specified plasterboard been fixed to the Hebel Supercrete Panel with screws nominated in the Hebel Supercrete Acoustic Wall Systems Design Guide? 8. Has specified steel stud frame been erected at the nominated offset from the Hebel Supercrete Panel wall? Has the frame been secured to the concrete in accordance with the project specifications? Has the correct insulation been installed in accordance with the manufacturers recommendations? 9. Has the specified plasterboard lining been installed and finished in accordance with manufacturers recommendations? Have the specified sealants been installed at the gaps between the plasterboard and concrete surfaces in accordance with manufacturers recommendations? 10. All Power outlets/switches offset by 600mm minimum? All services should be placed within the thickness of the furring channel or stud. All outlets/switches on the plasterboard and steel stud side of the wall shall be fully sealed.
35
AWS 2009
Technical Support
CFG Concrete Ltd and its nationwide network of distributors offers technical assistance in New Zealand. Visit www.hebel.co.nz for your nearest distributor who will offer free estimating services; technical support to project architects, engineers, builders and owners. Distributors arrange for their Licenced Hebel Supercrete Panel Installers and Supercoat Coating Applicators to undertake the install and coating works. They also train and monitor these licensed personnel.
Guarantee
Hebel Supercrete Autoclaved Aerated Concrete products and Supercoat coating products are guaranteed to be free of defect in material and manufacture. Installation workmanship and coating application work is guaranteed by the licensed personnel who perform this work. Substitution of this claddings listed components is not permissible and if alternative brands, materials or elements are used, this will void all guarantees. This guarantee excludes all other guarantees and liability for consequential damage or losses in connection with defective cladding, other than those imposed by legislation.
Health & Safety

Information on any known health risks of our products and how to handle them safely is shown on their package and/ or the documentation accompanying them. Additional information is listed in the Material Safety Data sheet. To obtain a copy, telephone 0800 443 235
For further information on products and our New Zealand wide Distributor Network Phone 0800 4 Hebel or visit www.hebel.co.nz
NONTOXIC
Authorised Distributor
ENERGY SAVING
LIGHT WEIGHT
NOISE RESISTANT
FIRE RESISTANT
ACCURATE
VERSATILE
LONG LIFE
RAPID ASSEMBLY
EASILY WORKED
BREATHABLE
Coatings Ltd
A Member of the CFGNZ Limited
CFG Concrete Ltd
67 Reid Rd, P.O. Box 2398 Dunedin, New Zealand. Phone: +64 3 455 1502 Fax: +64 3 456 3587 0800 4 HEBEL (0800 443235) www.hebel.co.nz
For your nearest distributor of Hebel Supercrete Products visit our website www.hebel.co.nz
The information presented herein is supplied in good faith and to the best of our knowledge was accurate at the time of preparation. No responsibility can be accepted by CFG Concrete Ltd or its staff for errors or omissions. The provision of this information should not be construed as a recommendation to use any of our products in violation of any patent rights or in breach of any statute or regulation. Users are advised to make their own determination of the suitability of this information in relation to their particular purposes and specific circumstances. Since the information contained in this document may be applied in conditions beyond our control, no responsibility can be accepted by us for any loss or damage caused by any person acting, or refraining from action as a result of this information. The systems detailed in this design guide are only to be used with Hebel Supercrete products manufactured by CSR Hebel Australia and distributed by CFG Concrete Ltd. This literature is not permitted to be used for other types of AAC, including Hebel Supercrete AAC from other manufacturers.

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Hebel Supercrete AWS Design Guide

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AWS 2009 Version 1.

Acoustic Wall Systems Design Guide

Acoustic Wall Systems Design and Installation guide

1.2 Why choose AWS?

1.4 Panel Sizes

The Vie Apartments

Harbour Watch Apartments

3.0 Acoustic Performance

Sound Transmission Loss. STL (dB)

STL curve of test wall STC60 STC55 STC50 STC45

1/3 Octave Band Centre Frequency (Hz)

3.2 NZ Building Code Requirements

3.3 Acoustic Analysis

4.0 Selection of AWS Type

*Depends on wall height refer Table 5.1 7

Insulation to project specification

Timber or steel framing both sides

Services may penetrate decorative wall without fire caulking

Hebel Adhesive at edge joints See details for base options

Type 1 Wall System

All 305 to 331 Depending on timber size & lining type

* or equivalent products of similar density

Detail 4.1.2 Vertical cross section of Type 1 Wall

Bracket fixed to framing and panel (refer to fixing detail)

Refer to Detail Section 12

Bradford or similar insulation as per project specification

3000mm max. panel height

600mm max. from bracket to joint in panel

Base detail. Refer to alternative methods in Section 12

Bradford or similar insulation to project specifications

75mm Hebel Supercrete Panel fixed edge to edge with Adhesive

Plasterboard lining fixed with 25mm needle point screws

Mortar as required between slab and panel

Detail 4.2.Type 2 Vertical cross-section

25mm needle point screws

50mm bugle head coarse thread screw

Plasterboard as per system requirements

Plasterboard as per system requirements 75mm Hebel Supercrete Panel

Rondo steel stud framing system

14-10 x 65mm hex head screw

Insulation as per system requirements

10mm fire and acoustic rated sealant

10mm fire and acoustic rated sealant Concrete slab

Type 2 Wall System

Fig. 4.1 Typical Type 2 wall installation

Fig. 4.2 Typical Type 3 wall installation

Detail 4.3 Type 3 Vertical cross-section

22mm IBS rod

J-track or deflection head fixed to soffit

Fire and acoustic rated sealant

25mm needle point screws

Plasterboard as per system requirements

Rondo steel stud framing system 75mm Hebel Supercrete Panel

Insulation as per system requirements

Wall System Type 3 STC 56

Wall width Fire rating Minimum

Wall System Type 4 Detail 4.1 Type 4 Vertical cross-section

STC Wall width Fire rating Minimum

N10 x 50mm bugle head coarse thread screw

14-10 x 65mm hex head screw

Insulation as per system requirements

10mm fire and acoustic rated sealant

14-10 x 100mm MP bugle head screw