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Head Office 2/89 Somerset Road
Campbellfield Vic, 3061 T. 03 9359 2336 F. 03 359 9306
E-mail. [email protected] www.ezylite.com.au
Installation Manual
Page 01 Contents
Page 02 Introduction Applications
Page 03 Material Properties Thermal properties Acoustic Properties
Page 04 Installation Details Roof to wall Details Eave Details Battening Walls
Page 065 Parapet Details Wall Details Slab Details
Page 06 Balcony Detail Sub Floor Detail
Page 07 Fixing Table
Page 08 Expansion Joints
Page 9 Installation Steps Page 10 Coating System
Page 11 Page 12 Warranty
Contents
Safety Wear
Cutting Tools
P-01
Ezylite Astrix inorganic panel with characteristics of 100% Asbestos free, non-toxic, odourless, non-combustibility, corrosion resistance, acid-base resistance, insulation, sound and thermal insulation and honeycomb interior structure. Astrix panel is truly a lightweight wall cladding designed for all fire and acoustic rating needs, a 50mm Astrix panel achieved FRL 120/120/120, in accordance with AS/1530. 4 2005 and Non - Combustible AS/1530, 1. Astrix panels are designed with Tong $ Groove (T&G) joining system placed on the long ends for easy installation, a team of two installers can install between 200- 600 SQM per day without the use of heavy lifting machines or special cutting tools. The weight of a 600 x 2100 x 50mm Astrix Panel is approximately 18 kg per panel, which is under the lifting limits endorsed by work safe Vic. Efficiency - Sufficient, predictable strength, durability and stability - Resists moisture, decay and bio-contamination - Non-toxic and non-hazardous to occupants and installers - Able to be installed efficiently and effectively, does not negatively impact on the eco systems and none of components are harvested or mined. - All components are reclaimed or recycled materials from other industries. - Does not require damaging maintenance, operations or disposal practices
P-02
Introduction
Applications All fire rated wall applications Highly recommended for acoustic wall applications. Widely applied in thermal insulation of building wall and roof; Lightweight aggregate of building material; Thermal insulation layer of kinds of industrial equipment and pipelines;
Detail 1: Tong & Groove
Important Note: This Manual is designed to ensure our product is installed correctly to serve
the purpose of protection against fire, Installers MUST follow all data provided in order to
obtain certification on completion. NO certificate will be issued if installation do not meet our
standards.
90 x 45 MGP10 Pine frame
Figure 3: Typical Wall Setup
Approved Fasteners 12-14g x 100
mm fixed @ 300 Centres
Thermal Properties. Astrix Panel tested in accordance with AS/NZS 4859.1 2005, provide a value of R-3.0 in a system combining Astrix Panel with R-2.2 fibreglass batts, making it excellent thermal efficiency with huge savings on energy bills. By increasing cavity and R value on fibreglass batts the efficiency will increase significantly. Acoustic Properties
Acoustic testing achieved Rw 63+ Ctr 51, with R-2.2 Fibreglass batts on timber frame lined with 10 mm Plaster board and 50 mm Astrix Panel.
Test Results to AS/1530,1, 2. 3, & 4
Test Results
Spread of Flame 0
Ignitability 0
Smoke developed 0
Toxic odours 0
Benefits
Lightweight Fire Rated Acoustic Rated Water Resistant (Not Waterproof) Anti Mould Termite Resistant High Impact Resistance Environmental Friendly Thermal Resistant Easy to cut and install Non contents of any hazardous
materials
P-03
Material Properties
R-2.2 fibreglass insulation
between studs
Detail 1 Acoustic Level
Astrix Panel Lined horizontally
Breathable sarking
10 mm plasterboard Internal wall
lining for non exposed face
38 x 16mm steel batten fixed
vertically onto timber or steel
frame
Steel Battens
Astrix panels can be installed directly to frame or on Metal/timber
battens, we Highly recommend the use of battens.
Detail 2 Wall section
Detail 4: Roof to Wall
Astrix Panel under
eave lining
Typical Timber/steel
Frame
Standard timber/ steel Frame
Roof & Eave Details
Detail 6: Astrix on Battens
Steel/Timber battens
Astrix Panel
Roof flashing
Render finish
Roof to Wall Detail
Approved fasteners
Astrix Panel
P-04
Astrix Panel
Eave Detail
Extend Astrix Panel
above eave
Astrix Panel
Detail 5: Option 2
Detail 3 Eave Option 1
External Corner Details
Astrix Panel Note: Installing Ezylite Astrix panels directly on timber/steel battens, we strongly recommend the use of steel battens which are fixed vertically on each stud spaced 450 centres. Fix breathable sarking on stud behind battens and R - 2.5 fibreglass wall batts between studs.
Breathable sarking
Direct Fix or Battens
Fire rated sealants between joints
Parapet Installation
Astrix Panel
Metal Capping
Internal Wall lining
Allow 30mm above roof line
Metal Flashing
Angle Flashing
Concrete Slab
Timber Frame
Detail 8: Astrix To Brick
Detail 9: Astrix To Concrete Slab
Flashing
Breathable sarking
Brick Wall
Roofing
Typical timber frame
Steel Battens
25mm
P-05
Note: Astrix panels must NOT be buried into ground or concreted, keep
panels Min 50mm above natural ground level
Detail 7: Wall to Roof
50mm
50mm
P-06
Astrix panels
Timber or Steel frame
Angle flashing fixed over
Astrix panels to provide
protection from water flow
One row of tiles to wall over
flashing min 300mm high
Balustrade
Floor tiles optional
Detail 10: Astrix To Balcony
Fix angle flashing over Astrix panels then one row of tiles to wall min 300 mm high to ensure Astrix panels are not submerged in water, balcony floor must flow away from wall.
Water flow
Astrix panels
Timber or steel frame
Angle flashing fixed to frame
Ground level
Detail 11: Astrix To Sub Floor
Keep water flow away from walls
Seal underside of panels where
water may come in contact
NOTE: DO NOT render on dusty surface, remove all dust and loose particles before any rendering or painting
Timber or steel frame 450 centres spacing
2100 L x 600 W @ 50 mm thick
External/Internal wall cladding
12-14g x 75 mm bugle C3 spaced @ 300
Fire rated sealants on all joints
Timber or steel frame with battens 38 x 16 steel battens fixed vertically on each stud
2100 L x 600 W @ 50 mm thick
External/Internal wall cladding
12-14g x 100 mm bugle C3 spaced @ 300 centres
Fire rated sealants on all joints
NOTE: All Timber or Steel Frame Must Be Lined With Breathable Sarking Wrap
Frame Type Panel Size Use Fasteners Adhesive
Fixing Table
16 mm Min
Fixing Astrix Panel into timber frame, allow Min 25 mm penetration.
14g x 100 mm Galvanized Bugle Screw
@300 mm Centres max
Timber Frame
50mm Astrix
Panel
P-07
Screws Fixing must be countersunk Max 1 mm
Detail 13: Fixing of Fasteners
Note. All installers to follow installation manual to avoid warrantee conditions, all fixings must be spaced min 300 centres apart, only use approved fire rated sealants and expansion joints min 5.0 to max 6.0 meters apart.
Special Note: Ezylite P/L will not provide certifications or warrantee on any wall cladding that are not
installed, rendered or painted in accordance with current installation manual.
Detail 12: Safety wear
Control joints must be installed to allow for structural movement. Allowance for movement must be made through the frame, Control joints must be installed at all construction joints in the building and at the following locations: Expansion joints should be placed over windows, doorways, and no more than 5 min and Max 6.00 meters apart. Horizontal expansion joints should be placed between levels to allow movements and shrinkage of floors. The details below are location of expansion joints on walls with windows and doorways.
Expansion Joints
Place Sealant as shown in diagram below & compress the panels to achieve best result
Fire Rated Sealant
Astrix Panel
P-08
Backing Rod
Timber Frame
Vertical Expansion Joint
Astrix Panel
Door Expansion Joint
Horizontal Expansion
Joint
NOTE: Install and render to rough side of panel only
NOTE: Install and render to rough side of panel only
Detail 14: Expansion Joints
Vertical Expansion Joint
Step 1 Ensure frame is level and free from any bows then place breathable sarking over all walls then fix steel battens vertically on each stud
Step 3 Ensure first row is level then continue installation, place fire rated sealants between all vertical joints.
AstrixTM Panel
Internal wall
lining
Timber frame
Breathable wall wrap
Astrix Panel
Approved fasteners Refer to Fixing Table
Timber frame
Step 2 Start from bottom, fix Astrix panel onto steel battens using 14g x 100 Bugle screws spaced @ 300 centres.
Step 4
Place expansion joints on
windows or door openings
(see expansion joint details)
Approved Fire Rated sealant Fire Rated Sealant between joints
38 x 16mm steel battens
Handsaw
Fire Rated Sealant
between all vertical & horizontal joints
40 mm
40
mm
Installation Steps
Timber or steel frame
Use Spirit Level for first
row panels installed
P-09
P-10
38 x 25 steel battens fixed vertically on each stud
Fix 14g x 100 Bugle screws @ 300 centres
38 x 16mm steel battens fixed vertically
Detail 15: Direct Fix or Battens
Detail 16: Installation on Battens
Coating System
1.1 Rendering (Ezylite Panels Must be coated after installation)
It is the renderer’s responsibility to use the appropriate compounds in the coating system sufficient to eliminate cracking of the joints under normal building settlement conditions. We recommend the use of Haymes, Quickcote or Dulux, other brands have not been used or tested on Ezylite products, and therefore we do not recommend the use of other brands. 1. Trowel on Patch approx 1 mm thick over joints then place 100mm wide alkaline-resistant
5mm weave fibre-glass mesh 160g/m2) over wet rendering. Apply aluminium angle beads to all external corners including window and door openings. Apply a 2nd layer of patch over fibreglass mesh while patch is still wet. (Allow drying time Min 24 hrs) refer to manufacturers specifications for drying periods.
2. Render entire board surface with polymer modified acrylic render Quickcote flexi patch/ Quickcote wet patch, or similar, at a minimum of 2mm thick.
3. The mesh is to be trowelled into the surface of the wet render, positioned just below the surface. Under no circumstances should the mesh be fixed to the walls and render applied over it. Overlap all fibreglass mesh sheets a minimum of 50mm.
4. Ensure the entire surface is level (taking into account the joint). Make sure that the joint is not proud of the remaining surface. Apply a second coat if the outline of the joint and fixings is not eliminated.
5. Apply trowel-on texture/colour to entire surface, Please note: all coatings must be applied and maintained in accordance with the coating manufacturer's instructions.
6. 7. Apply by roller (or mix in with colour when trowelling) sealer to entire wall. The sealer
protects the colour fading and waterproofing of wall.
NOTE: Install and render to rough side of panel only
Flexi wet patch
Base coat
Fiberglass mesh
Ezylite Astrix Panel
Color coat & Sealer
Detail 17: Render System
NOTE: DO NOT render on dusty surface, remove all dust and loose particles before any rendering or painting
Flexi wet patch
Warning: Ezylite P/L will not provide certifications or warrantee on any wall cladding that are
not installed, rendered or painted in accordance with current installation manual.
P-10
P-11
When cutting Astrix Panel ensure to wear safety glasses, dust mask and ear muffs, Astrix Panel Has been tested for Asbestos, Celica, and formaldehyde, with NO traced found. Refer to Material Safety Data Sheet (MSDS) for a full test result prepared by AWTA Testing Laboratory.
Dust Mask Ear Muffs Safety Glasses
Safety Wear
Power Saw
Cutting Ezylite Astrix panels can be achieved using a hand saw or power saw with standard tungsten tip blade, ensure to wear proper safety mask, goggles and safety glasses.
Cutting Tools
Hand Saw
Warning: Ezylite P/L will not provide certifications or warrantee on any wall cladding that are
not installed, rendered or painted in accordance with current installation manual.
Detail 18: Safety Wear
Detail 19: Cutting Tools
Warranty: EzyLite Pty Ltd warrants for a period of two (15) years ("the warranty period") from the date of purchase that all EzyLite products ("the product") will be free from defects due to faulty manufacture or materials, and will be resistant to cracking, rotting, fire and damage to the extent set out in EzyLite Pty Ltd published literature current at the time of installation, and strictly subject to the conditions set out below. (NOTE: RENDER MUST BE APPLIED AS SHOWN) The Warranty is strictly subject to the following conditions:- 1. The product, and any other products including fasteners and joining systems, applied to or used in conjunction with the product must be used and installed strictly in accordance with the approved installation manual at the time of installation. 2. Under no circumstances will EzyLite Pty Ltd be liable for defects arising from:- (a) A failure to use and/or install the product, or any products, strictly in accordance with the product installation manual. (b) Render coating system not recommended or applied to EzyLite Panels, Render system must be applied as stated in coating system. (c) Defective materials not supplied by EzyLite Pty Ltd ; or (d) Impact. 3. EzyLite Pty Ltd will not be liable for breach of Warranty, and no breach of Warranty claim will be accepted, unless the Claimant makes a written claim and provides proof of purchase within 30 days of the alleged defect becoming apparent. 4. This Warranty is not transferable under any circumstances without the prior written consent of EzyLite Pty Ltd. 5. A Claimant's sole remedy for breach of Warranty is (at EzyLite Pty Ltd option) that EzyLite Pty Ltd will either replace or repair the defect, supply replacement product, or pay for the cost of replacement or rectification of the affected product. 6. Under no circumstances shall EzyLite Pty Ltd be liable for any consequential loss, property damage or personal injury, economic loss or loss of profits, arising in Contract or negligence or howsoever arising. Without limiting the foregoing, EzyLite Pty Ltd will not be liable for any claims, damages or defects arising from or in any way attributable to poor or defective workmanship, defective materials or poor design or detailing, settlement or structural movement and/or movement or materials to which the product is attached, incorrect design of the structure, acts of God including but not limited to earthquakes, cyclones, floods or other severe weather conditions or unusual climatic conditions, normal wear and tear, or growth of any organism on any product surface. 7. The express warranties set out above are in lieu of all other representations, warranties or conditions, express or implied including but not limited to implied warranties or conditions of merchantable quality and fitness for a particular purpose, and those arising by statute or otherwise in law or from a course of dealing or use of trade and which are excluded to the fullest extent permitted by law. The joint and coating system must be applied by experienced applicators, as suggested by the joint and coating manufacturer. Any sand based rendering systems must use ionised sand bases. The selected joint and coating system must be applied to dry, clean sheet only. Application must be completed within 30 days of the sheets being fixed on site. It is the applicator's responsibility to use the appropriate compounds in the coating system sufficient to eliminate cracking of the joints under normal building settlement conditions.
P-12