Construction Manual Ver2

7/29/2019 Construction Manual Ver2

1/68

CONSTRUCTION MANUAL

Document Reference: CONSTRUCTION MANUAL_Ver2.doc 11/03 Page 1 of 68

CONSTRUCTION MANUAL

BUILDING SYSTEMS FORMODULAR HOUSING

Force 10 International Pty Ltd63 Factory Road, Oxley Qld 4075 Australia

PO Box 126, Brisbane Markets, Qld Australia 4106Phone: 61 7 3379 5200 Fax: 61 7 3379 5211

e-mail: [email protected]: http://www.force10.com.au

Note: This manual is subject to revision and updates are available on request from Force 10International Pty Ltd.

Issue Date: November 2003


2/68

CONSTRUCTION MANUAL


Table of Contents

1 INTRODUCTION..........................................................................................................................................................7

2 SAFETY REQUIREMENTS .......................................................... .............................................................. ................7

3 PRE-REQUISITES................................................................ .............................................................. ..........................7

3.1 FORCE 10DOCUMENTS .............................................................................................................................................7 3.2 STANDARDS..........................................................................................................................................................7 3.3 LOCAL AUTHORITY REQUIREMENTS .........................................................................................................................7 3.4 ALLOCATION OF WORK.............................................................................................................................................8 3.5 SERVICE CONNECTIONS ............................................................................................................................................8

4 CONSTRUCTION .......................................................... ........................................................... ....................................8

4.1 DURABILITY..............................................................................................................................................................9

5

SUGGESTED CONSTRUCTION PROCEDURE......................................................................................................9

5.1 STEP1.UNLOADINGMATERIALS .......................................................... ..........................................................95.2 STEP2.PREPARATIONOFSITE ...................................................... ............................................................ .......95.3 STEP3.FOUNDATION..........................................................................................................................................9 5.4 STEP4.FLOORFRAMINGANDSHEETING....................................................................................................10 5.5 STEP5.WALLSYSTEM......................................................................................................................................10 5.6 STEP6.FLOORBEARERS(SECONDSTOREY) ........................................................ ......................................105.7 STEP7.ROOFSYSTEM.......................................................................................................................................10 5.8 STEP8.WINDOWSANDDOORS ...................................................... ........................................................... .....105.9 STEP9.SERVICES...............................................................................................................................................10 5.10 STEP10.CEILING................................................................................................................................................10 5.11 STEP11.CUPBOARDSANDJOINERY ..................................................... ........................................................10

6 UNLOADING AND STORING MATERIALS.........................................................................................................106.1 PARTNUMBERS ......................................................................................................................................................11

6.1.1 Wall Components ................................................................ ............................................................ ...............116.1.2 Floor Components............................... ........................................................... ................................................12

7 FOUNDATIONS .......................................................... .............................................................. ..................................12

7.1 GENERAL ................................................................................................................................................................12 7.2 FOOTINGS................................................................................................................................................................12

7.2.1 Setting Out......................................................................................................................................................127.2.2 Boundary Pegs ............................................................ ........................................................... ........................127.2.3 Corners...........................................................................................................................................................12 7.2.4 Profiles ....................................................... .................................................................. ..................................13

7.2.5 Excavation............................................................... ............................................................... ........................147.2.6 Stump /Post Foundation Types.......................................................................................................................147.2.7 Stump /Pile Length and Set-Out.....................................................................................................................157.2.8 Position ................................................................... ............................................................... ........................15

7.3 CONCRETE ..............................................................................................................................................................16 7.4 POUR THE CONCRETE SLAB ....................................................................................................................................16

8 FORCE 10 FLOOR SYSTEM .............................................................. ................................................................. .....17

8.1 BEARERS AT GROUND FLOOR.................................................................................................................................17 8.2 FLOORJOISTS..........................................................................................................................................................19 8.3 FLOORSHEETING ....................................................................................................................................................20 8.4 FLOORFLASHING ....................................................................................................................................................22 8.5 BEARERCOVER.......................................................................................................................................................23

9 FORCE 10 WALL SYSTEM ........................................................... ............................................................ ...............26

9.1 THE GRID SYSTEM ..................................................................................................................................................26


3/68

CONSTRUCTION MANUAL


9.2 WALL FLOORBRACKETS ........................................................................................................................................26 9.3 GENERAL EPOXIED INSTALLATION GUIDELINES (REFER TO SPECIFICATION)..........................................................28

10 FORCE 10 WALL PANEL SIZES AND CODING..............................................................................................29

10.1 ERECTINGEXTERNALWALLPANELS ................................................... .......................................................31

10.2 EXTERNALPANELRUNS..................................................................................................................................32 10.3 ERECTINGDOUBLEJOINERYPANEL ...................................................... ......................................................3410.4 ERECTINGINTERNALWALLS.........................................................................................................................34 10.5 PLASTICCOVERSTRIPS ................................................................ ............................................................... .....3510.6 INTERNALWALLS ....................................................... ............................................................ ..........................3610.7 ERECTINGDIAGONALWALLPANELS..........................................................................................................37

11 FORCE 10 TWO STOREY CONSTRUCTION ............................................................... ....................................39

11.1 TWOSTOREYCONSTRUCTION.......................................................................................................................39 11.2 BEARERSOVERGROUNDFLOORWALLS....................................................................................................39 11.3 BEARERSOVERGROUNDFLOORDOUBLEPANELS..................................................................................40 11.4 FLOORJOISTS ....................................................... ........................................................... ...................................4111.5 TWOSTOREYCEILINGBATTENS...................................................................................................................42 11.6 TWOSTOREYFLASHINGS................................................................................................................................43

12 FORCE 10 POST AND BEAM SYSTEM ................................................................ .............................................43

12.1 75X75RHSWALLPOST/COLUMN ........................................................... ......................................................4412.2 COLUMNBETWEENPANELS...........................................................................................................................44 12.3 RHSBEAMS .......................................................... ................................................................ ...............................45

13 FORCE 10 ROOF SYSTEM...................................................................................................................................48

13.1 ROOF.....................................................................................................................................................................48 13.2 TRUSSASSEMBLY ................................................................ ............................................................... ..............4813.3 PRELIMINARYWORK ................................................................ ........................................................... ............4813.4 FIXINGOFTRUSSES ...................................................... ................................................................ ....................4813.5

GABLEENDROOF.......................................................... ........................................................... .........................49

13.6 TRUSSBINDERS .............................................................. ........................................................... ........................5113.7 ROOFPURLINS....................................................................................................................................................52 13.8 EAVESPURLINS ............................................................ ........................................................... ..........................5313.9 HIPROOFASSEMBLY........................................................................................................................................54 13.10 GIRDERTRUSSES ....................................................... ................................................................ ....................5613.11 HIPPURLINS....................................................................................................................................................58 13.12 EAVESLININGS ................................................... ............................................................ ...............................5913.13 ROOFSHEETING.............................................................................................................................................59 13.14 GABLEENDCLADDING................................................................................................................................59 13.15 SPOUTINGANDFASCIA................................................................................................................................59

13.15.1 Fixing and Fitting Facia /Gutter Brackets (Fall)....................................... ................................................60

14 SOUND CONTROLS ............................................................. ......................................................... ........................60

15 FIRE CONTROL.....................................................................................................................................................61

16 INTERNAL JOINERY............................................................................................................................................61

16.1 CUPBOARDS........................................................................................................................................................61 16.2 SKIRTINGBLOCKS.............................................................................................................................................61

17 SERVICES................................................................................................................................................................62

17.1 PLUMBING...........................................................................................................................................................62 17.2 ELECTRICAL ............................................................. .................................................................. ........................62

18 CEILINGS ....................................................... ................................................................ .........................................62

18.1 CEILINGBATTENS .......................................................... .............................................................. .....................6218.2 CEILINGLINING ...................................................... ........................................................... ................................63


4/68

CONSTRUCTION MANUAL


19 DOORS .................................................... ........................................................... ......................................................63

19.1 DOORS ........................................................... ........................................................... ............................................63

20 FINISHING TRADES ....................................................... .............................................................. ........................66

20.1 TRADES ..................................................... ............................................................ ...............................................6620.2 WETAREAS .......................................................... ........................................................... ....................................66

21 EXTERNAL FINISHING .................................................. ............................................................. ........................66

21.1 WINDOW DETAILS ...................................................................................................................................................66 21.2 WINDOWCOVERSTRIPS...................................................................................................................................67

22 FINISHING SYSTEM........................................................ ............................................................. ........................67

22.1 EXTERNAL FINISH REQUIREMENTS ..........................................................................................................................67 22.2 FORCE 10 RECOMMENDED EXTERNAL FINISHES ......................................................................................................67 22.3 FACADES.................................................................................................................................................................67 22.4 INTERNAL FINISHING ..............................................................................................................................................68


5/68

CONSTRUCTION MANUAL


Table of Drawings

Figure 1 Panel Identification Sticker __________________________________________________________________11Figure 2 Panel Identification Sticker 2_________________________________________________________________11Figure 3 Boundary Site Layout_______________________________________________________________________12Figure 4 Profiles (Stump /post Foundations) ____________________________________________________________13Figure 5 Inner profiles _____________________________________________________________________________14Figure 6 String Line Profiles ________________________________________________________________________14Figure 7 Cross Bracing_____________________________________________________________________________15Figure 8 Measure and Align Stumps /posts to stringline ___________________________________________________15Figure 9 Stumps /posts - concreting details_____________________________________________________________16Figure 10 Fix bearer_______________________________________________________________________________17Figure 11 Adjoining bearer _________________________________________________________________________17Figure 12 Corner bearers on stumps /posts _____________________________________________________________18Figure 13 Intersecting bearers _______________________________________________________________________18Figure 14 Intersecting bearer on stump ________________________________________________________________18Figure 15 Joists to bearers __________________________________________________________________________19Figure 16 Non load bearing and non bracing panel ______________________________________________________19

Figure 17 Floor system overview of components _________________________________________________________20Figure 18 Applying adhesive ________________________________________________________________________20Figure 19 Staggered floor sheets _____________________________________________________________________21Figure 20 Floor Sheet fixings ________________________________________________________________________21Figure 21 Panel sheet layout ________________________________________________________________________22Figure 22 Sheet joint and diaphragm floors_____________________________________________________________22Figure 23 Wall /floor flashing________________________________________________________________________23Figure 24 Wall bearer flashing_______________________________________________________________________23Figure 25 Deck bearer flashing ______________________________________________________________________24Figure 26 Flashing - Mitred details ___________________________________________________________________24Figure 27 Grid location ____________________________________________________________________________26Figure 28 Chalk out grid lines _______________________________________________________________________26

Figure 29 Hole layout______________________________________________________________________________27Figure 30 Wall/floor bracket ________________________________________________________________________27Figure 31 Slab hold down bracket ____________________________________________________________________27Figure 32 Epoxy Installation guidelines (Internal 90mm and External 120mm) _________________________________28Figure 33 Single module panels ______________________________________________________________________29Figure 34 Double module panels _____________________________________________________________________30Figure 35 45 Degree module panels___________________________________________________________________30Figure 36 Corner floor bracket layout _________________________________________________________________31Figure 37 Corner floor bracket layout - Slab floor _______________________________________________________31Figure 38 Corner intersecting panel___________________________________________________________________32Figure 39 Panel Erection Runs_______________________________________________________________________33Figure 40 Window head support______________________________________________________________________34Figure 41 Textureline PVC Cover strip ________________________________________________________________35

Figure 42 External corner PVC cover strip _____________________________________________________________35Figure 43 Internal wall fixings - Wall panel on gridline ___________________________________________________36Figure 44 Internal wall fixing Wall panels off gridline ____________________________________________________37Figure 45 Internal wall panels Wall panels on concrete slab on ground_______________________________________37Figure 46 Diagonal panel fixing______________________________________________________________________38Figure 47 45 Degree floor bracket ____________________________________________________________________38Figure 48 Diagonal panels Shifting of centreline_________________________________________________________39Figure 49 Wall Tee bracket__________________________________________________________________________40Figure 50 Bearers supported by ground floor panel ______________________________________________________40Figure 51 Lintel bearer plate ________________________________________________________________________41Figure 52 Lintel bearer plate to bearer ________________________________________________________________41Figure 53 Joists to bearers __________________________________________________________________________42Figure 54 Two storey ceiling battens __________________________________________________________________42Figure 55 Fitting wall/floor flashing __________________________________________________________________43Figure 56 Two storey galvanised flashing ______________________________________________________________43Figure 57 One way column Figure 58 Two way column________________________________________________44


6/68

CONSTRUCTION MANUAL


Figure 59 Three way column Figure 60 Four way column _____________________________________________44Figure 61 Column to panel connection_________________________________________________________________45Figure 62 Column to panel connection_________________________________________________________________45Figure 63 Beam to truss fixings ______________________________________________________________________46Figure 64 Beam to column fixings ____________________________________________________________________46

Figure 65 Beam to panel junction_____________________________________________________________________47Figure 66 Beam bracket to external corner panel ________________________________________________________47Figure 67 Factory assembled trusses __________________________________________________________________48Figure 68 Truss fixing details ________________________________________________________________________49Figure 69 Typical gable end truss ____________________________________________________________________49Figure 70 Gable End Detail _________________________________________________________________________50Figure 71 Gable end truss assembly #1 ________________________________________________________________50Figure 72 Gable end truss assembly #2 ________________________________________________________________51Figure 73 Gable end roof space brace _________________________________________________________________51Figure 74 Truss binders ____________________________________________________________________________52Figure 75 Purlin joints _____________________________________________________________________________52Figure 76 Purlin location screws _____________________________________________________________________52Figure 77 Purlin location Details_____________________________________________________________________53

Figure 78 Purlin location screws _____________________________________________________________________53Figure 79 Gable end purlins_________________________________________________________________________54Figure 80 Gable end purlin details____________________________________________________________________54Figure 81 Typical hip end roof layout _________________________________________________________________55Figure 82 Hip end bottom chords_____________________________________________________________________55Figure 83 Typical girder truss _______________________________________________________________________56Figure 84 Fixing hip end bottom chords________________________________________________________________56Figure 85 Corner assembly__________________________________________________________________________56Figure 86 Fixing centre jack rafter at apex _____________________________________________________________57Figure 87 Hip roof module sizing and framing layout _____________________________________________________57Figure 88 Hip ridge purlins _________________________________________________________________________58Figure 89 Hip ridge purlins at apex ___________________________________________________________________58Figure 90 Fixing roof purlins to hip ___________________________________________________________________59Figure 91 Eaves linings ____________________________________________________________________________59Figure 92 Skirting Blocks ___________________________________________________________________________62Figure 93 Door frame finish ________________________________________________________________________63Figure 94 Door fixings details drawing ________________________________________________________________64Figure 95 Window /door packer detail fixings___________________________________________________________64Figure 96 Window fixing detail drawing _______________________________________________________________65Figure 97 Packer details____________________________________________________________________________65Figure 98 Wet area fixings __________________________________________________________________________66Figure 99 Window Reveals __________________________________________________________________________66


7/68

CONSTRUCTION MANUAL


1 Introduction

The full details of the Force 10 Building Systems Construction procedure are contained in this easy to follow

manual.

The stage by stage format is designed to ensure that any possible problems during construction are avoided.

2 Safety Requirements

Site Safety must be a prime concern at all times Refer to the attached documents for details.

3 PRE-REQUISITES

3.1 Force 10 Documents

All Force 10 home owners are supplied with the following documentation for a Building Consent application andfor construction.

ITEM QUANTITY

A3 CONSTRUCTION DRAWINGS 2

A4 LAMINATED CONSTRUCTION DRAWINGS 1

CONSTRUCTION MANUAL 1

BILL OF MATERIALS 1

COMPLIANCE MANUAL /ENGINEERING CERTIFICATES 1

CRATINGS LIST 1

3.2 STANDARDS

The specific design details the foundations required and other special aspects referred to for construction inaccordance with local standards. You will need a copy of the relevant standard to work with.

3.3 Local Authority Requirements

Your local authority may require the following information before a Building Consent can be issued:

A floor plan at each level

An elevation of each external wall

The type and location of each foundation element

CAUTION

PERSONAL PROTECTIVE EQUIPMENT MUST BE WORN ATALL TIMES WHEN OPERATING EQUIPMENT

BE AWARE OF DANGEROUS SITUATIONS THAT MAY

ARISE AT ANY TIME ON A CONSTRUCTION SITE


8/68

CONSTRUCTION MANUAL


Adequate information on all walls and subfloor, floor, and roof framing, including the type andlocation of each subfloor brace, diagonal brace, and wall bracing element and the number of wallbracing units assigned to each wall bracing element.

The type and location of roof cladding and ceiling and wall linings

Building Consent application form

After the local authorities have issued Consent, please contact your Force 10 Customer Services Officer for anyalterations the local authority may require to approve plans. Only stamped plans are used and consideredvalid. There will be an extra fee payable if changes are to be made to existing plans unless the changes arerequired to obtain a Building Consent.

3.4 Allocation of Work

The following table identifies the recommendations for who may carry out the work for the various tasks.

A Work that may be undertaken by building ownerB Work that must only be undertaken by registered Tradesperson

C Work that is recommended undertaken by specialist subcontractor

Work Who may carry out thework

Concrete or masonry foundation walls B

Post or stump foundation A

Concrete-slab-on-ground A and C

Construction of floor, walls and roof A

Installation of linings, floor sheathing and roofcladding

A

Exterior joinery A and C

Electrical work B

Plumbing and Drainage BGas B

Carpentry and tiling A and C

Plasterboard fixing and stopping A and C

3.5 Service Connections

Connections associated with electricity, gas and telephone must be lodged with the appropriate serviceauthorities, through a registered Tradesperson. Drainage and water connections are covered by the Buildingapproval for the project.

4 CONSTRUCTIONNow you are ready to start your Force 10 building and transform it to your very own home. The constructionprocedure follows a step-by-step pattern and is normally adhered to, although it may vary according to sub-contractor availability.

After the arrival of your Force 10 kit, check carefully for any damage. Contact your Force 10 CustomerServices Officer (CSO) ([email protected]) and report any damages or missing parts within threedays, or no responsibility can be expected.


9/68

CONSTRUCTION MANUAL


4.1 Durability

Steel floor framing, sub floor framing, steel roof trusses and connections have a zinc coating which providesprotection against corrosion resulting from wetting during construction and temporary leakage associated withdamaged cladding. The long term durability is dependent on the steel components being maintained in a dry

condition.

Where floor, wall and roof framing is protected from the exterior environment i.e. completely encapsulated byweather tight linings, flashings and claddings, this condition is met.

The strength and stiffness of wall panels is related to the sandwich panel action which in part relies on thedurability of the polyurethane foam that fills the cavity.

It is expected that the durability of the foam will exceed 40 years and that adherence of the foam to the fibrecement board will also exceed this period. Some injection of foam into wall panels may be necessary beyondthis time to maintain structural integrity.

5 SUGGESTED CONSTRUCTION PROCEDUREFollowing is a suggested construction program:

5.1 STEP 1. UNLOADING MATERIALS

Check all items against the given Bill of Materials list. Arrange covered storage for materials in dry conditionsclear of the ground (Note always use dunnage to store materials off the ground).

5.2 STEP 2. PREPARATION OF SITE

Check survey information and position of services. Remove topsoil and prepare site for hardfill (slab-on-

ground) or for excavation (stump /pile or foundation wall footings).

Ensure the finished ground surface immediately adjacent to the building is shaped adequately to facilitatesurface drainage away from the building and the site and building floor levels meet the provisions of requiredstandards.

Arrange for the excavation and placement of all buried services, eg. water, gas stormwater and sewer drains.

5.3 STEP 3. FOUNDATION

Slab-on-ground:Erect profiles, place and compact hardfill. Excavate footings, place Damp Proof Membrane (DPM), install

formwork and fix footing and slab mesh reinforcing in place.

Call for local authority inspection prior to placing concrete. Set out holding down bolts in the wet concretewhere desired as an alternative to chemical anchors.

All concrete work should be carried out in accordance with the relevant standard.

Using Stumps or a Post foundation:Erect profiles, excavate for footings, fabricate floor framing on stumps /posts, lift and support framework inposition and call for Local authority inspection before placing concrete in the footings. Note that some footingswill be anchor stump /pile footings.


10/68

CONSTRUCTION MANUAL


5.4 STEP 4. FLOOR FRAMING AND SHEETING

Bolt bearers to foundation wall or stump /pile tops (This is required for stumps /posts before placing footingconcrete - see step 3).

Fix joists into bearers. Erect stairs.

Fit stump /pile bracing in accordance with the specific design. Lay flooring sheets and screw fix into position.For a slab-on-ground, wall panels are fixed directly to the slab.

5.5 STEP 5. WALL SYSTEM

Following the wall panel layout plan, mark out grids and wall panel positions. Fix floor brackets, fit floorflashings, then erect walls.

Check that all wall frames are plumb.

5.6 STEP 6. FLOOR BEARERS (SECOND STOREY)

Bolt bearers to wall tee brackets which are fixed to bottom storey wall panels and install joists, flooring sheetsand walls as in Steps 4 and 5 above.

5.7 STEP 7. ROOF SYSTEM

Place trusses, purlins, binders, barge, fascia and gutter. Fix gable end braces to gable ends if applicable. Onhip roof, fix girder trusses first, then standard trusses between.

Brace up roof where required and fix purlins. Attach gutter brackets, fascia/barge, gutter (valleys if applicable)and do not forget downpipe droppers.

Frame up eaves and gables, fix ceiling and soffit battens, and fix soffit linings (where applicable).

5.8 STEP 8. WINDOWS AND DOORS

Window frames are factory pre-fitted. Fixing of pre-hung door frames. Fit door furniture.

5.9 STEP 9. SERVICES

Installation of plumbing and drainage. Run all electrical cables prior to plastering or installing ceiling. This workmust be undertaken by a licensed Tradesperson.

5.10 STEP 10. CEILING

Locate ceiling battens and fix ceiling linings.

5.11 STEP 11. CUPBOARDS AND JOINERY

Install cupboards and fix skirtings, joinery and architraves.

6 UNLOADING AND STORING MATERIALS

If crane and forklift services are unavailable on the site, packs should be opened on the truck and manhandledto the ground. Check all items against Bill of Materials list.


11/68

CONSTRUCTION MANUAL


Components should be kept dry and under suitable covers during construction. Take special care of cement,plaster, etc. if provided. Stack materials into related component groups, ensuring access to all items ismaintained. Timber linings and mouldings should be stacked carefully to prevent damage or warping.

Learn names of components and how and where they are to be used. At each stage of the project lay out

materials in the proximity of their eventual position. This will save time and increase the speed of erection.

Extreme care should be exercised when handling glass. Windows should be supported and carried to theappropriate position according to the Panel Plans. Do not apply loads directly to glass.

6.1 Part Numbers

The major components of the wall have code labels affixed, which describe their size, type and finish. Eachcode number will have a corresponding number on the component layout plans within the drawings supplied, toassist in the erection of the house.

Carefully check the location of each part on the plans before assembly. The erection process will be greatlyassisted if parts are laid out or marked out prior to commencement. The product type is identified by a series ofletters and numbers with the following meanings:

A, B,C = Width of the panel

X, I = External or Internal panel

W = Window panel

D = Door panel

1 to 10 = Window height

Prefix 45 = Diagonal panel

SP = Special Panel

6.1.1 Wall Components

Solid wall panels are prefixed with the type code which relates to width and whether the panel is an internal orexternal panel. Window panels are prefixed with the letter W and door panels with the letter D. The numberfollowing is a code, indicating the type, size and finish of the panels. The following quality control labels areaffixed to panels

Always check the product type label on solid wall panels to determine if the panel is an internal or anexternal panel (designated by an I or X respectively). Never use an Internal panel on an External wall.

Electrical panels contain either single or double 48mm vertical ducts, which can be seen at either end ofthe panels. Always check for the existence of this duct before erecting external panels in accordance withthe electrical layout.

With windows and door panels a label advising the fitting of jambs and removal of packers is attached tothe panels.

Figure 1 Panel Identification Sticker

Figure 2 Panel Identification Sticker 2


12/68

CONSTRUCTION MANUAL


6.1.2 Floor Components

It is not necessary to mark bearers and joists as the module length and type are self evident.

7 FOUNDATIONS

7.1 General

Foundations will comprise one of the following:

Steel square hollow section (SHS) ordinary or braced stumps

Concrete slab on ground.

The details of the foundation for each project are part of the specific design in the project drawings.

7.2 Footings

7.2.1 Setting OutIt is important to note that the precise layout of footings is essential to the assembly of the system. The exactlocation of stumps /posts is critical at this stage of the construction. We recommend you have a Tradespersonon site for this procedure.

7.2.2 Boundary PegsCheck survey information and boundary pegs. Ensure that the building is correctly sited on the block and thatall Local authority requirements are met.

7.2.3 CornersMark corners of building with temporary pegs, roughly square by measuring diagonal distances and adjustingline position of the pegs until the diagonal measurements are equal. Check again that all pegs are still clear of

boundary requirements.

Figure 3 Boundary Site Layout


13/68

CONSTRUCTION MANUAL


7.2.4 Profiles

Profiles are to support the string lines used in the setting out of the proposed new building. They areconstructed using timber pegs, with timber horizontal rails nailed to the pegs at a determined height which is

normally the top of finished floor level. The length and width of the building are marked onto the top edge of thehorizontal rail. A nail is then fixed either side of the mark to identify the mark and make sure the string isalways in the same position. You will then be required to write on the horizontal rail, the purpose of this stringline, eg. building line, centre of stump, etc.

Figure 4 Profiles (Stump /post Foundations)

After the profile pegs have been driven into the ground, the next thing to do is determine the floor height andmark it onto the corner peg. For a suspended floor, ground floor level must be a minimum of 650mm fromfinished ground level or to local authority requirements.

For a concrete slab, the finished floor level must be poured to the local authority requirements. The dumpylevel can now be set to the height. Transfer this mark to the other pegs and nail the horizontal rail onto thepegs with the top edge on the mark.

Note: Make sure profiles are kept back from building line approx. 900mm when setting out the profiles.


14/68

CONSTRUCTION MANUAL


Figure 5 Inner profiles

If the building has breaks in the building line, further profiles will be required. These can be constructed using 2pegs and 1 rail.

Figure 6 String Line Profiles

7.2.5 Excavation

Check the specific design for stump /pile or/and foundation wall footing details.

Excavate holes for footings in accordance with the project requirements and clean out all holes carefully.

7.2.6 Stump /Post Foundation Types

Refer to the specific design for layout of braced and ordinary stumps /posts.

Lengthen bracing set to its maximum extension and position other end diagonally across bay to the bottom ofthe next stump /pile. Mark and drill dia.17mm hole through stump /pile and fix bracing with M16 x 120 bolts


15/68

CONSTRUCTION MANUAL


Figure 7 Cross Bracing

7.2.7 Stump /Pile Length and Set-Out

The length of stumps /posts will very dependant upon the slope of the land. Position stumps /posts beside therespective holes. (Refer to the Site Footing Plan).

Figure 8 Measure and Align Stumps /posts to stringline

7.2.8 Position

Support the whole assembly over the excavation so that the stump /pile is accurately located to the centre ofthe grid line and to the string lines strung from profiles. The bottom of the stump /pile should be at least 150mmabove the bottom of stump /pile hole.


16/68

CONSTRUCTION MANUAL


7.3 Concrete

Figure 9 Stumps /posts - concreting details

Check that the structure is both square and level. Subject to an inspection of the footing by local BuildingInspector or Certifier, concrete can be poured to all foundations. Stumps /posts should be temporarilysupported while pouring and compacting the concrete. Care should be taken not to disturb the structure duringthe pouring of concrete.

Check the final position of the stumps /posts before the concrete sets. Adjust position as necessary andrecompact the concrete ensuring all stumps are plumb.

7.4 Pour the Concrete Slab

Force 10 recommends that you employ tradespersons to complete the slab. The concrete slab is a veryimportant part of the construction and if it is not completed in a satisfactory manner then there will be trouble allthe way through construction of the building.

Concrete slab-on-ground foundation details (where applicable) will be in accordance with a specific designbased on a soil investigation (A minium of 20 MPa is the Design Strength).

Specific designs will detail all elements necessary, such as ground beams and stumps /posts and also give thedetails for slab mesh and other foundation requirements.

Items to check as work progresses on the slab are:

The building has been sited in the correct position on the section of land

The drainage contractor has completed all under slab drainage and has council approval

Stumps /posts and ground beams are constructed in accordance with the specific design When used the polythene damp proof membrane is in place and all joints are taped together

All reinforcing steel is correct

Accurate formwork dimensions

Note: If required by the local authority to be installed care must be taken not to puncture the damp proofmembrane and any joins and holes must be taped. For slab on ground construction the flashing fitted over thejoint between the wall panel and the edge of the slab must lap at least 50mm with the damp proof membrane(DPM) so that the wall/floor bracket is protected from external moisture.

Bolt the wall panels to the slab at each end using the 85 x 50 x 8mm yellow zinc coated steel wall floorbrackets.

Refer to the fixing appendix attached to the manual for the correct fixing to be used.


17/68

CONSTRUCTION MANUAL


8 FORCE 10 FLOOR SYSTEM

8.1 Bearers at Ground Floor

Starting at one corner, align the two (2) holes at end of bearer with bolts attached to stumps /posts

Figure 10 Fix bearer

Abut next bearer and continue to secure bolts and washers.

Figure 11 Adjoining bearer

At the corner, simply lap flanges of bearers, align holes in lapped top flanges with M16 tapered bar and securethe position by fixing a wafer Tek screw in the corner.


18/68

CONSTRUCTION MANUAL


Figure 12 Corner bearers on stumps /posts

Where a bearer intersects with a row of bearers:

Figure 13 Intersecting bearers

Figure 14 Intersecting bearer on stump

Insert web of intersecting bearer into gap between flanges of abutting bearers.

Locate holes over the stumps /posts.

Align holes in top flanges with M16 tapered bars.

Secure bottom flanges to stump /pile with bolts, nuts and washers.

Cut the top flange of the

bearer only to accommodateintersecting bearers

The slot is to be formed on site


19/68

CONSTRUCTION MANUAL


Again check that all bearers are level and at the required height. If levelling is required, locate highestpoint, jack and support all other bearers to this level.

8.2 Floor Joists

Distribute floor joists in accordance with the Floor Framing plans. Stack the floor joists into related modulesizes, ensuring access is maintained.

Before fixing any floor joists, start from one end and set out the floor joists at the centres shown on the Framingplan.

Locate the ends of floor joists between flanges of bearers at each of the 5mm pre-punched holes. The centreline of the floor joist flanges should be aligned to these pre-punched holes. Fix one joist in place with 10-16 x16 wafer Tek screws through these holes into both the top and bottom flanges of the joist.

Figure 15 Joists to bearers

Note: Joists are more effective if they are rotated and not clipped in facing the same way

Where non-load bearing / non bracing wall panels run between floor joists, the detail is as shown in Figure 16and no blocking is required.

Figure 16 Non load bearing and non bracing panel


20/68

CONSTRUCTION MANUAL


Figure 17 Floor system overview of components

8.3 Floor Sheeting

Particleboard flooring sheets supplied with each kit set are 3600 x 900 x 22mm thick and have a polypropylenetongue. Plywood flooring sheets can also be used as a flooring alternative provided all edges are supported byfloor framing. Always start on the long side of the building making sure that the first sheet is parallel to theoutside of building. The sheeting should finish flush with, but not extend past the exterior edge of the bearerflange.

Adhesive is to be applied to all floor joists and bearers. Remove oil and dust from all surfaces. Apply theadhesive only to small segments at a time to ensure good bonding to the flooring.

Figure 18 Applying adhesive

Note: Great care must be taken with the first run of flooring, ensuring that the edges of the first sheet are placedat the end of the first run. This eliminates waste and ensures that joints are staggered, thus providing astronger floor.


21/68

CONSTRUCTION MANUAL


Figure 19 Staggered floor sheets

Adhesive used should be modified acrylic adhesive suitable for bonding timber to metal (i.e. Ramset Safe-T-Bond or similar).

The flooring is then to be screwed using 10-16 x 45 CSK wing Tek screws to every joist and bearer. Perimeteredge fixings should be spaced at 150mm centres maximum. Intermediate fixings should be spaced at 200mmcentres maximum.

Note: Refer to the flooring manufacturers specifications for more detailed information.

Figure 20 Floor Sheet fixings

Fixings at perimeter bearers should be staggered so that the floor sheeting is restrained by both flanges of thebearer.

When sheet flooring is used as part of a diaphragm screw fixings are required at 150mm centres around the

perimeter of each sheet and at 200mm centres to intermediate supports.

Where polypropylene tongue jointers are used, additional screw fixings are required at joist crossings asshown.

When sheet flooring is used as part of a diaphragm floor screw fixings are required at 150mm centres aroundthe perimeter of each sheet and at 500mm centres to intermediate sheets. Where polypropylene tongue joinsare used additional screw fixings are required at the joint crossing as shown in Figure 22.


22/68

CONSTRUCTION MANUAL


Figure 21 Panel sheet layout

Figure 22 Sheet joint and diaphragm floors

Note: Compressed Fibre Cement Floor Fixing is 10-16x45 SEH Wing Tek

Hint: Dot drill the floor sheet with a masonry drill to get the head of the screw below the finish sheet line.

Nogs are required for the long side of the sheet and joints screwed with 10-16x25 Hex Tek.

Ensure Hydro Epoxy is applied to all butt joints of the sheets see the manufacturers instructions.

8.4 Floor Flashing

Fit the Stainless Steel wall/floor flashing from edge of flooring and between the flooring and bearer.

Note: This flashing must be fitted before erecting the wall panels.

The flashing will carry on around the perimeter of the building. This flashing can be fixed after the flooring hasbeen laid.

Note: Inspect the joint regularly for sealant separation on the outer flashing and replace as necessary.


23/68

CONSTRUCTION MANUAL


Figure 23 Wall /floor flashing

8.5 Bearer Cover

After all external wall panels have been erected, the Wall Bearer Flashing can now be fixed. This flashing iswrapped over the bearer profile and screwed off.

Figure 24 Wall bearer flashing

At decks/patios, a smaller but similar (to Wall Bearer) Deck Bearer Flashing is fixed to sit over the timberdecking and wrapped over the bearer profile and screwed off.


24/68

CONSTRUCTION MANUAL


Figure 25 Deck bearer flashingThese flashings will carry on around the perimeter of the building and decks.

At corners, trim and fold Wall Bearer/Deck Bearer Flashing as per diagram. Run a bead of silicone between alloverlaps and fix tabs with pop rivets.

Note: Corner of flashing should be mitred to assist placement of bearer cover and prevent penetration of waterinto floor sheeting.

Figure 26 Flashing - Mitred details


25/68

CONSTRUCTION MANUAL


Internal /External Flashing Details

Wall Deck Flashing

Wall /Floor Flashing

Wall /Slab Flashing


26/68

CONSTRUCTION MANUAL


9 FORCE 10 WALL SYSTEM

9.1 The Grid System

The assembled floor frame has groups of four (4) 14mm holes at every 500mm centres in the bearers. Theseholes should be used to establish the location of the 1000 grid on the floor sheeting and for fixing of floorbrackets at the intersection of grids. A grid line occurs at every second group of holes at the centre of the four(4) holes layout.

Figure 27 Grid location

After accurately chalking out all the grids on the flooring, mark location of the wall panels and identify their

panel codes from the Panel Layout plan.

Figure 28 Chalk out grid lines

9.2 Wall Floor Brackets

Find the position and direction of floor brackets at ends of each panel. Drill two (2) 12mm holes through theflooring to align 10mm bolt holes in the bracket. It is important that these holes accurately align with two of thepre-punched holes in the top flange of the bearers. This may be achieved by drilling through the floor at centre

of the pre-punched holes with a small electric drill using a 3mm (1/8) bit. Alternatively, the four holes layoutcan be determined from the intersection of the chalked grid lines.


27/68

CONSTRUCTION MANUAL


When drilling through the top flange of the joist to fix wall brackets and flooring ensure that all swarf is removedfrom the lower flange of the floor framing members.

Figure 29 Hole layout

Locate bracket with vertical leg directly over the intersection of the grid and fix to floor with two M10 bolts.Ensure placement of washers on bearer side of fixing.

Figure 30 Wall/floor bracket

Note:All external panels and any other panels that are positioned over a bearer must be fixed through the floorand bearer with two M10 bolts. For any non-load bearing and non-bracing internal wall panels which are notpositioned over a bearer, no drilling is required, the brackets are fixed with two M10 x 50 bolts or 2/14-10x50Hex Tek Type 17 Screws through the two smaller holes in the floor brackets.

For a concrete slab situation, place Brackets over M12-120 epoxied in threaded rod. Refer to Figure forinstallation details.

Figure 31 Slab hold down bracket


28/68

CONSTRUCTION MANUAL


9.3 General Epoxied Installation Guidelines (Refer to Specification)

Drill a hole to the size and embedment required.

Blow the hole clean with compressed air, brush the hole, and blow itclean again. Holes should be clean and sound. They may be dry ordamp, but should be free of standing water or frost.

Be sure to properly balance the mixing nozzle prior to dispensing andwhen changing cartridges. Fill the hole approximately half way withepoxy starting from the rear of the hole. Slowly with the static mixingnozzle as the hole fills to avoid creating air pockets within the hole.

Push the threaded rod into the hole while turning slightly to ensurepositive distribution of the epoxy. Be sure the rod is fully seated atthe bottom of the hole and that some epoxy has flowed from the topof the hole. The threaded rod should be free of dirt, grease, oil, etc.

Allow the epoxy to cure for the specified time prior to applying anyload.

Do not disturb or load the anchor until it is fully cured.

Figure 32 Epoxy Installation guidelines (Internal 90mm and External 120mm)


29/68

CONSTRUCTION MANUAL


10 FORCE 10 WALL PANEL SIZES AND CODING

The Force 10 wall panel system which consists mainly of two sizes of panels in each of the single module,double module and 45 degree infill panels.

Figure 33 Single module panels


30/68

CONSTRUCTION MANUAL


Figure 34 Double module panels

Figure 35 45 Degree module panels


31/68

CONSTRUCTION MANUAL


Panel heights are 2435mm, 2700mm and 3000mm. Wall panels are either solid or leave openings forwindows and doors.

The type of sheeting on wall panels is dependent upon the type of wall finish required. Generally, the outside

sheeting of exterior panels is Fibre Cement textureline board whilst the external face is bevelled edge FibreCement Board to provide a bond for plastering.

Both external and internal panels have PVC conduits for electrical wiring. Panels are symmetrical, so they areable to be fixed to the floor using either end (top and bottom). This feature allows conduit placement to be eitheron the left or on the right side of the panels.

10.1 ERECTING EXTERNAL WALL PANELS

Always start erecting wall panels at an external corner and work around it. At any external corner one panel willend on grid intersection and one panel will be off grid (i.e. typically these panels would be 1000mm and 962mmrespectively.)

Figure 36 Corner floor bracket layout

At the corner, establish which wall panel will end off the grid line intersection (i.e. 1000mm panel). Drill twoadjacent 12mm holes through the flooring, directly below the on-grid panel, to match the holes in the end ofthe bearer. This method will be similar for a concrete slab-on-ground; this will mean that on-grid panel(1000mm) will be fixed to the cast-in external M12 bolt via the Floor Brackets in lieu of drilling or by the epoxybolt system..

Figure 37 Corner floor bracket layout - Slab floor

Commence by bolting the first two Floor Brackets of the long wall to the suspended floor concrete slab orfoundation wall.

NOTE: The horizontal legs of these two brackets should face each other. Then bolt down the bracket for theend wall panel so that its horizontal leg faces toward the corner.


32/68

CONSTRUCTION MANUAL


Continue bolting brackets around the perimeter allowing for doors and windows.

All external brackets should be securely bolted to the floor/slab and flashing fixed prior to erecting panels.

See the previous note re the Stainless Steel Flashing.

Figure 38 Corner intersecting panel

Refer to panel layout drawing and select panels. Check coding on panel label against layout drawings.

Raise panel between floor brackets. Align holes in bottom of panel with holes in the upright of FloorBrackets and fix M16 bolts in place.

Insert Truss Bracket to top of panel and fit M16 bolt through the studs and Truss Bracket.

Secure Structural tie angles with four 10-16x16 wafer Tek screws, each at equal spacings.

Tighten the M16 nut and check for plumb in two directions.

Fix structural tie angles top and bottom of panels with 10-16x16 wafer Teks.

Always start walls by erecting both panels at an external corner and erect the first panel of each intersectingwall as work progresses. This will provide a stable and plumb wall that will resist damage which could becaused by a wind gust.

10.2 EXTERNAL PANEL RUNS

Working from an erected corner, check location and fixing of Floor Bracket at next grid. Panel Alignment

Brackets must be fixed between studs of all adjoining panels to ensure correct alignment of walls. Generally,single solid panels and single window panels require two Panel Alignment Brackets each located about 1/3from the top and bottom of panels.

Undo M16 bolt at Floor Bracket below, raise next panel into position ensuring the floor flashing engages atbottom and re-fasten the M16 bolt to fix the bottom studs of both panels to the floor bracket.

At top of panels place a Truss Bracket between adjoining studs and fix together with a M16 x 32 bolt.

Continue this process for the remaining panels in the wall.

Erect the first panels of intersecting walls as approached.


33/68

CONSTRUCTION MANUAL


Figure 39 Panel Erection Runs


34/68

CONSTRUCTION MANUAL


10.3 ERECTING DOUBLE JOINERY PANEL

Erection of these panels is similar to that of external solid wall panels.

NOTE: Adjoining studs of door and window panels should be fixed together, 300mm either side of the midpoint of the opening using 12-14x30 Hex Tek screws.

For Double Joinery Panel (external or internal), remove bolt from top of lintel and screw fix a M12x250 threadedrod into hole. The B size double panels have two 12mm holes @ 38mm centres in the lintel head. Use onlythe hole from one end which directly falls over the grid when fixing trusses (i.e. 1000mm from the nearest trussbracket). Place Window Head Support Bracket over the threaded rod.

Note: The bolt that has been removed can be saved for the use of the 45 Bracket as described in the followingsections.

Figure 40 Window head support

10.4 ERECTING INTERNAL WALLS

All internal walls should be erected before trusses are placed. All wall panels must be fixed to both floor andtruss to meet structural requirements. The exception to this is non-load bearing walls which run between andparallel to floor joists.

These walls must be fixed to ceiling battens using the Truss Bracket.


35/68

CONSTRUCTION MANUAL


10.5 PLASTIC COVERSTRIPS

External wall panels are finished with textured board on the outside face and flat finish board on the inside face.Interior lining is tapered edge board. If this is the case on your Force 10 kit, you will then be required to insert a

patterned PVC jointer strip into joints between abutting external panels.

The jointer is inserted during erection of external panels.

The tongue of these cover strips should be notched so as not to interfere with the connection brackets betweenthe panels. In most cases this will require notching at the top, bottom and in the centre of the cover strip.Leave at least one barb on the tongue.

Use a timber off-cut of about 600x100x50mm as a softener when hammering in cover strips to prevent bruisingand this will also keep cover strips straight.

Figure 41 Textureline PVC Cover strip

Figure 42 External corner PVC cover strip


36/68

CONSTRUCTION MANUAL


10.6 INTERNAL WALLS

The system for locating internal walls is through the use of the four hole floor layout as described in the TheGrid System section.

When erecting an internal wall panel:

determine the location of the wall

align to grid and fix floor bracket by two M10x50 bolts for floor system or one M16 hex head bolt withLoxin shield for concrete slab.

raise the panel and fix into place

insert the Truss Bracket between top of panels.

Figure 43 Internal wall fixings - Wall panel on gridline

Where possible place the long sheet sides of internal panels to face the wet areas. This will allow easiersealing at the floor.


37/68

CONSTRUCTION MANUAL


Figure 44 Internal wall fixing Wall panels off gridline

Figure 45 Internal wall panels Wall panels on concrete slab on ground

10.7 ERECTING DIAGONAL WALL PANELS

Refer to Panel Layout plan and select the appropriate panel. Raise panel into position and align 45 DegreeBracket to stud holes at the top and bottom of adjoining panels.

Note: It is important to note the 45 Degree panel is not actually at 45 Degrees Refer to Figure 53.

Position 45 Degree Brackets to each corner of the panels, insert stud on bracket through M16 hole in 45

degree Panel Stud, fit washer and secure nuts.


38/68

CONSTRUCTION MANUAL


Figure 46 Diagonal panel fixing

These 45 Degree Brackets should be used to fix the top and bottom of diagonal panels to adjoining panels and

are used in conjunction with Floor Brackets and Truss Brackets.

Figure 47 45 Degree floor bracket

NOTE: The centre line of the 45 Degree Panel does not line up exactly with a line drawn between grid lineintersections.


39/68

CONSTRUCTION MANUAL


Figure 48 Diagonal panels Shifting of centreline

11 FORCE 10 TWO STOREY CONSTRUCTION

11.1 TWO STOREY CONSTRUCTION

Two storey construction is similar to single floor construction. The ground floor and walls are constructed inexactly the same manner. However, at the top of the ground floor wall, different brackets are used to fix thefloor structure of the upper floor (also referred to as First Floor). The floor structure uses the samecomponents as the ground floor, although the layout and brackets may be different. Flashing also varies.

11.2 BEARERS OVER GROUND FLOOR WALLS

When bearers are supported by ground floor walls, the Wall Tee Brackets are used to provide the structuralconnection. This bracket is fixed between the top of adjacent panels with an M16 bolt in the same manner asfixing a Truss Bracket.


40/68

CONSTRUCTION MANUAL


Figure 49 Wall Tee bracket

Figure 50 Bearers supported by ground floor panel

Bearers are bolted to the bracket with four M10x25mm bolts at the intersection of each panel. The majority of

these bearers are perimeter bearers of the first floor.

11.3 BEARERS OVER GROUND FLOOR DOUBLE PANELS

Where bearers sit over double joinery window or door panels, locate the M12 hole on top of the lintel. Thishole is in the centre of the lintel. Thread a M12 x 220mm threaded rod down into the hole until the top of the

rod is about 10mm below the top of the panel. Loosely thread two locknuts onto the rod.

Align the top of a lintel bearer plate to the top edge of the panel and centre of the middle hole directly over therod.


41/68

CONSTRUCTION MANUAL


Figure 51 Lintel bearer plate

Thread the M12 rod into the plate stopping it flush with the top of the plate. Secure by tightening the locknuts,

one each against the plate and lintel. Bolt bearer to bracket with M10x25mm bolts and nut.

Figure 52 Lintel bearer plate to bearer

11.4 FLOOR JOISTS

Distribute floor joists in accordance with Floor Framing plans. (Stack floor joists into related module sizes,ensuring access is maintained).

Before fixing any floor joists, start from one end and set out the floor joists at the centres shown on the Framing

plans.

Locate the ends of floor joists between flanges of bearers at each of the 5mm pre-punched holes. The centreline of the floor joist flanges should be aligned to these pre-punched holes. Fix 1 off 10-16 x 16 wafer Tekscrew through these holes into both the top and bottom flanges of the joist.


42/68

CONSTRUCTION MANUAL


Figure 53 Joists to bearers

Floor sheeting to upper floor may then be fixed to bearers and joists.

Great care must be taken with the first run of flooring, ensuring that the edges of the first sheet are placed atthe end of the first run. This eliminates waste and ensures that joints are staggered, thus providing a strongerfloor.

Note: Floor nogs may be required for compressed fibre cement flooring.

Refer to Section FLOOR SHEETING for fixings.

11.5 TWO STOREY CEILING BATTENS

Ceiling battens for ground floor of two storey construction are continuous C Section which are fixed to the

underside of the joists. These are used to fix the top of non load bearing walls.

Figure 54 Two storey ceiling battens

Truss Brackets are used at the top of adjacent panels in these instances in lieu of a Wall Tee Bracket. Drill a12mm hole in the middle of the Ceiling Batten, fit hole over truss bracket and secure with M12 flanged nut. Fixthe ceiling battens to the underside of joists with 10-16x16 Wafer Tek screws.


43/68

CONSTRUCTION MANUAL


11.6 TWO STOREY FLASHINGS

Around the perimeter of the upper floor, fit the Stainless wall/floor flashing so that it covers the flooring and thebearer.

Figure 55 Fitting wall/floor flashing

Upon erection of the upper floor walls, lay a 5mm bead of silicone sealant on the top face of the flashing.

After all external wall panels have been fix the two storey wall bearer flashing. This flashing capped over thewall floor flashing and over the bearer profile and screwed off, ensures a good continuous bond between theflashing and the top flange of cover.

Figure 56 Two storey galvanised flashing

The construction of the remainder of the building is as previously described for single storey construction.

12 FORCE 10 POST AND BEAM SYSTEM

The details which follow in this section are typical and shall be confirmed or varied by a specific design for eachproject as appropriate. It is assumed that these parts of the system are fully enclosed with claddings andlinings.


44/68

CONSTRUCTION MANUAL


12.1 75X75 RHS WALL POST / COLUMN

The following column specifications are normally used for all Force 10 wall columns:

75 x 75 x 3.0 SHS 75 x 75 x 5.0 SHS

These columns are used in various places throughout the building (i.e., between wall panels, stand alonesupporting carport and support structural steel).

12.2 COLUMN BETWEEN PANELSThese columns are situated between several wall panels in various combinations. (Refer to the figures below).

Figure 57 One way column Figure 58 Two way column

Figure 59 Three way column Figure 60 Four way column

Column faces are fabricated with pre-drilled tapped holes or brackets for connection to wall panels or beams.These connections vary to accommodate their purposes and positions.

The column face that connects to wall panels has a 17mm diameter hole with M16 Kwikspan nut welded to theinside of column wall, top and bottom. This is known as side option P. This face will be positioned next to awall panel and will be bolted together with M16x32 Kwikspan bolt to top and bottom.


45/68

CONSTRUCTION MANUAL


Figure 61 Column to panel connection

Figure 62 Column to panel connection

12.3 RHS BEAMS

The following beam specification is used for most Force 10 truss beams:

125 x 75 x 3 RHS


46/68

CONSTRUCTION MANUAL


These beams come in lengths of 1 module, 2 module, 3 module and on a rare occasion, 4 modules. They areused for supporting trusses and outrigger rafters over carport areas.

All beams have pre-drilled holes for bolts connecting to trusses, and to columns use 12-24x32 Series 500 HexTeks.

Figure 63 Beam to truss fixings

RHS beams are fixed to the column (post) bracket with four (4) 12-24 x 32 series 500 hex Tek screws at eachend and using one (1) M12x250 cup head for the remainder of the intermediate holes to truss bottom chordfixings.

Where beams meet perpendicular to a wall, the RHS beams are fixed to a similar bracket at the panel junction,

also with four (4) 12-24x32 series 500 hex Teks.

Note that two (2) 14-10x25 Hex Teks are used to locate this bracket centrally with a 3mm gap at the top, andfour (4) 12-14x30 Hex Teks to screw the bracket into the panel studs.

Figure 64 Beam to column fixings


47/68

CONSTRUCTION MANUAL


Figure 65 Beam to panel junctionAt external corners where beams require connection, the method is the same as above, but a stud section and6mm fibre-cement packer need to be fixed within the void of the external corner to provide a similar connection.

Figure 66 Beam bracket to external corner panel


48/68

CONSTRUCTION MANUAL


13 FORCE 10 ROOF SYSTEM

13.1 ROOF

Erection of roofing can be greatly simplified by undertaking some preliminary work prior to raising of trusses.This work includes:

Marking out and fixing of location screws for purlins

Fixing of gable end framing and

Marking centre lines of grid on top chord if trusses support diminishing trusses.

Figure 67 Factory assembled trusses

13.2 TRUSS ASSEMBLY

Trusses are manufactured and assembled on the Force 10 factory floor ensuring that every component is fitted

and screw fixed in place, ready for transportation to the job site.

Trusses can also be assembled and then dismantled for containerising ready for shipment to an overseas jobsite. They are then unloaded on site and ready for re-assembly. All connections are labelled to allow ease ofreassembly.

13.3 PRELIMINARY WORK

Stand standard trusses side by side so that they align accurately with each other. On the top chords, marklocations of lower edge of the purlins, using a string line. Refer to Truss Framing plan for purlin spacing.

13.4 FIXING OF TRUSSES

Check that all Truss Brackets are vertical and tightened securely. Lower standard trusses, ensuring the trussesrun across the house, as per plan over the 125mm truss brackets through the hole provided at the intersectionof the top and bottom chord at the external walls. Place 20 degree truss washers over the rod and top chordand tighten with M12 flanged nut.


49/68

CONSTRUCTION MANUAL


Figure 68 Truss fixing details

13.5 GABLE END ROOF

The trusses at gable ends must be framed to support exterior sheeting. This framing should be fixed before thetruss is raised and bolted in position.

Figure 69 Typical gable end truss


50/68

CONSTRUCTION MANUAL


Figure 70 Gable End Detail

Fix 40mm x 65mm angles to the outer flange of the top chord of gable end truss with 10-16 x 16 wafer Teks.

Fix the pre-cut top hat section gable end vertical struts to angles with 10-16 x 16 wafers at the top and with 14-10 x 25 at bottom to truss bottom chord.

Gable end struts should be spaced at 500mm centres.

Figure 71 Gable end truss assembly #1Raise and bolt trusses into place at end of building (Section Fixing of Trusses) Check that the gable endtrusses are plumb, the gable end trusses are braced (roof space brace) with a length of top hat section fixed atthe top chord of the gable end trusses and tied back to the binder which is fixed to the top of the bottom chordof all trusses.


51/68

CONSTRUCTION MANUAL


Figure 72 Gable end truss assembly #2

Figure 73 Gable end roof space brace

13.6 TRUSS BINDERS

Check that all trusses are true and vertical. Run two rows of top hat section down the length of the building ontop of the bottom chord of trusses, as per engineers drawings. Fix Truss Binders to each truss with two 14-10x25 Hex Tek screws.


52/68

CONSTRUCTION MANUAL


Figure 74 Truss binders

13.7 ROOF PURLINS

Roof purlins are in modular lengths and must be fixed so that the purlin ends finish on a grid line or the centreline of truss top chords. The different Module lengths are used to stagger purlin joints.

Figure 75 Purlin joints

Place purlins in position resting against locating screws, fix flanges to truss top chord with four (4) 14-10 X 25

Hex Tek screws. The purlin location screw may be re-used after securing on flange).

Figure 76 Purlin location screws


53/68

CONSTRUCTION MANUAL


Figure 77 Purlin location Details

Figure 78 Purlin location screws

13.8 EAVES PURLINS

A special purlin for a gable roof which overhangs the gable end, and provides support for soffit linings andbarges


54/68

CONSTRUCTION MANUAL


.

Figure 79 Gable end purlins

These purlins are placed in line with the other purlins running the length of the building. Place these purlins ontop of the last two (2) trusses so that the part which supports the soffit lining rests on the top chord bottom

flange and abuts to its web.

Figure 80 Gable end purlin details

Fix the rear end of the gable end purlins to the centre line of the second truss top chord with two (2) 14-10 x 25Hex Tek and then four (4) at the gable end trusses.

13.9 HIP ROOF ASSEMBLY

The hip roof is erected in a similar manner to the conventional roof. All structural framing components areerected over grid lines for ease of location.


55/68

CONSTRUCTION MANUAL


Figure 81 Typical hip end roof layout

Figure 82 Hip end bottom chords


56/68

CONSTRUCTION MANUAL


13.10 GIRDER TRUSSES

Assemble and raise Girder truss #1 over the first grid back from the end wall and secure with flanged nuts andthe 20 Washer to the Truss Brackets as previously described for the fixing of standard trusses.

Figure 83 Typical girder truss

Continue to erect the remaining girder trusses which have #2, #3, or #4 as their coding.

To close in the one (1) metre gap between the end walls and Girder Truss #1 for ceiling lining, use a top hatsection called a Hip End Bottom Chord.

Figure 84 Fixing hip end bottom chords

Place the hole ends of Hip End Bottom Chords over the truss brackets along the end walls.

Fix other end of hip end bottom chord to flange of Girder Truss #1 bottom chord with two (2) 10-16x16 waferTek screws. These screws should be fixed from the underside of the flange so as not to interfere with laying of

ceiling sheeting. These Hip End Bottom Chords are spaced at every 1000mm centres starting from side walls.

Figure 85 Corner assembly


57/68


58/68

CONSTRUCTION MANUAL


13.11 HIP PURLINS

Place a hip purlin each side of (and parallel to) the line ofthe hip ridge. These purlins should start in line with theend of trusses or jack rafters and follow the hip until they

intersect with the ridge purlin from the other side.

Figure 88 Hip ridge purlins

Fix wherever they cross the jack rafters and top chords of trusses with two (2) 14-10x25 Hex Tek screws.

Where hip purlins intersect with each other at apex of hip cut to lengths so that one flange of each overlaps and

fix together with 14-10x25 Hex Teks.

Figure 89 Hip ridge purlins at apex

Mitre the other hip purlins to run into and rest on bottom flange of the hip ridge purlins. Fix overlapping flangeswith 14-10x25 Hex Tek screws.


59/68

CONSTRUCTION MANUAL


Figure 90 Fixing roof purlins to hip

To be used in cases where portals are attached to the slab. The Threaded rod placed in position beforeconcrete is set. The Portal is then secured in place with heavy-duty nut/washer.

13.12 EAVES LININGS

Fit ceiling batten to bottom chord of truss at wall. Nest edge of lining into groove at the back of fascia and fix inplace.

Figure 91 Eaves linings

13.13 ROOF SHEETING

Roof sheeting systems, including cladding, flashings and fixings shall be installed in accordance with clearlypresented and adequate technical literature supplied by the manufacturer.

13.14 GABLE END CLADDING

Gable end cladding, including cladding, flashings and fixings, shall meet the provisions of relevant standards.

13.15 SPOUTING AND FASCIA

Spouting and fascia shall be fit for purpose and meet the relevant provisions of the relevant standard. Spoutingand fascia shall be fixed to truss chords in accordance with clearly presented and adequate technical literaturesupplied by the manufacturer. Spouting shall have a slope to facilitate drainage and the design shall ensurethat if blockage occurs that overflow into the roof space will not occur.


60/68

CONSTRUCTION MANUAL


13.15.1 Fixing and Fitting Facia /Gutter Brackets (Fall)

There are various facia and gutter systems used and the appropriate tradesperson and manufacturersspecifications should be used. Always ensure that there is adequate fall in the gutter to allow water to drain

from the roof area. Refer Fig 91.

14 SOUND CONTROLS

These are various ways to reduce sound readings in a Force 10 building. Refer to the attached chart forroofing or contact Force 10 for further information regarding the use of CSR SoundChek.


61/68

CONSTRUCTION MANUAL


15 FIRE CONTROL

To improve the fire resistance rating of force 10 systems CSR Fyrchek can be used over the Fibre cement

panels as attached drawing. For further information refer to Force 10 International.

16 INTERNAL JOINERY

16.1 CUPBOARDS

Fixing of cupboards will vary upon the type of unit and finishes. The units generally come pre-assembled to siteand should be fixed to wall and sealed around edges to prevent dirt or moisture penetrating behind the unit.Always fasten directly into the steel panel studs when fixing units to walls.

16.2 SKIRTING BLOCKS

After all panels are erected, glue fix skirting blocks to flooring at 500 centres under open recess of panel withadhesive. The vertical face of these angles should be flush with the face of the panel. Allow the adhesive

adequate time to set before fixing skirting.


62/68

CONSTRUCTION MANUAL


Figure 92 Skirting Blocks

Skirtings should be fixed with 6-20 x 50 CSK Wing Tek screws. Where possible fix skirting after installation ofplumbing and electrical services as this will allow easier location of services.

17 Services

17.1 PLUMBING

All plumbing services should be brought up through the floor, inside cupboa