OZONE PANEL TECHNICAL MANUAL - Archicentre Australia...Detail 2.4 Concrete Foundation Insulated with EPS 17 DETAIL – WALL 3.1-3.11 19 Detail 3.1 Connection Between Wall and Foundation

OZONE PANEL TECHNICAL MANUAL

©OZONE PANEL PTY LTD OCTOBER 2017 ozonepanel.com

RESISTANCE TO FIRERESISTANCE TO IMPACT

RESISTANCE TO MOISTURERESISTANCE TO ROTTINGRESISTANCE TO TERMITESRESISTANCE TO CYCLONES

RESISTANCE TO EARTHQUAKESRESISTANCE TO SOLVENTSCFC & HYDROCARBON FREE

Non-technical imagery contained within this document is for display purposes only.

©OZONE PANEL PTY LTD ozonepanel.com

BUILDINGTHE CHANGEPANELS

THAT FIT OUR ENVIRONMENT

CONTENTSEXECUTIVE SUMMARY 5

CONSTRUCTION ELEMENTS 1.1-1.4 7

Detail 1.1 Ozone Panel 8

Detail 1.2 Connectors 9

Detail 1.3 Bottom Plate and Top Plate 10

Detail 1.4 Window Opening Frame 11

FOUNDATIONS 2.1-2.4 13

Detail 2.1 Rough Concrete Foundation 14

Detail 2.2 Insulated Foundation with Panels 15

Detail 2.3 Insulated Foundation with Panels 16

Detail 2.4 Concrete Foundation Insulated with EPS 17

DETAIL – WALL 3.1-3.11 19

Detail 3.1 Connection Between Wall and Foundation 20

Detail 3.2 Connection Between Wall and Foundation 21

Detail 3.3 In-line Connection 22

Detail 3.4 Corner Connection 23

Detail 3.5 T-Section 24

Detail 3.6 Framing Openings 25

Detail 3.7 Framing Openings 26

Detail 3.8 Critical Openings 27

Detail 3.9 Window Openings 28

Detail 3.10 Top Plate Overlapping 29

Detail 3.11 In-line Structure 30

DETAIL – FLOOR 4.1-4.3 33

Detail 4.1 Connection between Walls and Up-fl oor structure 34

Detail 4.2 Connection between Walls and Up-fl oor structure 36

Detail 4.3 Ozone Panel Floor Installation 37

DETAIL – ROOF 5.1-5.10 41

Detail 5.1 Connection Between Roof and Wall 42

Detail 5.2 Connection Between Roof and Wall

– Square Cut Eave 43


– Vertical Eave 44

Detail 5.4 Pre-Engineered Wood Trusses 45

Detail 5.5 Ridge Connection 46




Detail 5.9 Valley Connection 50

Detail 5.10 Panel Connection on Rafter 51

DETAIL – PERIPHERALS 6.1-6.11 53

Detail 6.1 Rubber 54

Detail 6.2 Sealant 55

Detail 6.3 Floor Sheathing 56

Detail 6.4 Thermal Insulation 57

Detail 6.5 Hydro Insulation 58

Detail 6.6 Hydro Insulation 59

Detail 6.7 Acoustic Elements 60

Detail 6.8 Fire Protection 61

Detail 6.9 Fire Traps 62

Detail 6.10 Fire Place 63

Detail 6.11 Fire Protection 64

DETAIL – DUCTS 7.1 67

Detail 7.1 Ducts 68

CODEMARK™ CERTIFICATION 69

MATERIAL SAFETY DATA SHEET 80

PAGE PAGE

4

EXECUTIVE SUMMARY

5

Welcome to the 21st Century House.

Today’s home needs to be many things. It needs to insulate us not just from the elements and their harshest extremes, but from the increasing bustle of society. It must be long lasting and fl exible enough to create all manner of architectural styles. It must be quick and effi cient to build. And all without costing the Earth.

The concept of Structural Insulated Panels was fi rst developed in the 1930’s with a research program investigating methods of conserving U.S. forest resources. Early converts include visionary architect Frank Lloyd Wright.

Today, the Ozone Panel represents the pinnacle of Structural Insulated Panel Technology. Two facades of Oriented Strand Board (OSB3), sourced from FSC certifi ed tree roots and forest off-cuts, sandwich our revolutionary Polyisocyanurate foam. This renders the Ozone Panel termite, cockroach and moisture resistant. But it’s particularly benefi cial in fi re prone areas, as Polyisocyanurate is a Thermoset foam, specifi cally designed not to melt even under bushfi re conditions.

Our unique formulation (which also grants superior acoustic and thermal qualities), exclusive to the Ozone Panel System, results in a CodeMark certifi ed structural rating, meaning it can be applied to structural walls as well as internal walls, fl ooring and roofi ng. Yet it’s innate fl exibility allows the Ozone Panel to withstand impacts like earthquakes and cyclonic winds. But incredibly, and as the information on the following pages will demonstrate, Ozone Panels are lightweight enough for one carpenter with two unskilled labourers to construct a single story residence to lock up within days.

And most importantly, the savings aren’t limited to time and money: The Ozone Panel is made from 65% recycled, environmentally friendly components and the manufacturing process is completely CFC free.

We are excited to introduce the innovative Ozone Panel and usher in the dawn of Australia’s 21st century house.

Haydn WrightOzone Panel

6

‘Time waste differs from material waste in that there can be no salvage. The easiest of all wastes and the hardest to correct is the waste of time, because wasted time does not litter the fl oor like wasted material.’ >Henry Ford

TRUTRUCONSTNSTTRUCTION ELEMEENTS

Section

1

7

The ingenious design and light weight of the Ozone Panel System

dramatically saves time by reducing process replication and the need

for multiple trades.

In fact, two workers with nail guns can complete 1.25m of framing,

bracing, insulation and conduits every seven minutes.

CONSTRUCTION ELEMENTS

Detail 1.1 Ozone Panel1

ozonepanel.com

These drawings are guidelines only and designers should ensure compliance with AS standards.Section

8


Detail 1.2 Connectors1

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These drawings are guidelines only and designers should ensure compliance with AS standards.Section

9

1Section


Detail 1.3 Bottom Plate & Top Plate

Ozone Panel

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These drawings are guidelines only and designers should ensure compliance with AS standards.

1Section


Detail 1.4 Window Opening Frame

Ozone Panel

Ozone Panel

Top plate

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‘Science is a first-rate piece of furniture for a man’s upper chamber, if he has common sense on the ground fl oor.’ >Oliver Wendell Holmes

12

IONS

Section

2

13

Like other building methods, the Ozone Panel System

relies on a strong foundation. But unlike other systems,

the Ozone Panel allows enormous fl exibility in the way

you can build and is ideal for a variety of architectural

styles and techniques.

The Ozone Panel: revolutionising building from the

ground up.

2Section

FOUNDATIONS

Detail 2.1 Rough Concrete Foundation

Ozone Panel

Plasterboard

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2Section

FOUNDATIONS

Detail 2.2 Insulated Foundation with Panels

Ozone Panel

Plasterboard

Plasterboard

Ozone Panel

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2Section

FOUNDATIONS

Detail 2.3 Insulated Foundation with Panels

Plasterboard

Plasterboard

Ozone Panel

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2Section

FOUNDATIONS

Detail 2.4 Concrete Foundation Insulated with EPS

Ozone Panel

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The perfect form of housing for our environment was created by indigenous Australians thousands of years ago, providing both shade and airflow to moderate temperature.

18

Section

3

19

But from fi rst European settlement, we imported

building concepts from a very different climate

(without importing the climate itself!) and built boxes

designed to trap heat. Eventually, after generations

of stifl ing summers, we chose to burn more coal to

generate electricity to power air conditioners to cool

those boxes down. An inefficient, expensive and

environmentally unsustainable ‘solution’.

Today, new concepts in residential design, which

acknowledge climate, seasonal cycles, terrain, aspect

and the modern challenges of the world in which we

live, in combination with the Ozone Panel system and

it’s unique insulative characteristics, will help

passively protect your home from climatic extremes,

resulting in lower greenhouse emissions and lower

energy costs.

Your new home and the Ozone Panel

System. A perfect marriage of form

and function.

WALLS

3Section

DETAIL – WALL

Detail 3.1 Connection Between Wall and Foundation

Plasterboard

Ozone Panel

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3Section

DETAIL – WALL

Detail 3.2 Connection Between Wall and Foundation

Ozone Panel

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3Section

DETAIL – WALL

Detail 3.3 In-line Connection

Plasterboard

Plasterboard

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3Section

DETAIL – WALL

Detail 3.4 Corner Connection

Plasterboard

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3Section

DETAIL – WALL

Detail 3.5 T-Section

Ozone Panel

Plasterboard

Plasterboard

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3Section

DETAIL – WALL

Detail 3.6 Framing Openings

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3Section

DETAIL – WALLS

Detail 3.7 Framing Openings

Ozone Panel

Ozone Panel

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3Section

DETAIL – WALLS

Detail 3.7 Critical Openings

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3Section

DETAIL – WALL

Detail 3.9 Big Openings

Ozone Panel

Ozone Panel

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3Section

DETAIL – WALL

Detail 3.10 Top Plate Overlapping

Plasterboard

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3Section

DETAIL – WALL

Detail 3.9 Big Openings

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31

OZONE PANEL

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32

‘Are you really sure that a fl oor can’t also be a ceiling?’ >M.C. Escher

LOOR

Section

4

33

4Section

DETAIL – FLOOR

Detail 4.1 Connection Between Ozone Panel Walls and Up-Floor Structure

Ozone Panel

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4Section

DETAIL – FLOOR

Detail 4.1 Connection Between Ozone Panel Walls and Up-Floor Structure (Cont.)

Ozone Panel

Ozone Panel

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4Section

DETAIL – FLOOR

Detail 4.2 Connection Between Ozone Panel Walls and Up-Floor Structure

Ozone Panel

Ozone Panel

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4Section

DETAIL – FLOOR

Detail 4.3 Ozone Panel Floor Installation

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These drawings are guidelines only and

designers should ensure compliance with AS standards.

4Section

DETAIL – FLOOR


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4Section

DETAIL – FLOOR


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These drawings are guidelines only and

designers should ensure compliance with AS standards.

40

To escape the island labyrinth that he himself had built and then been imprisoned in by a treacherous king, master builder Daedalus created for himself and his son Icarus pairs of wings from wax and feathers.

Daedalus cautioned his son not to fl y too close to the hot sun, lest the wax melt. But Icarus, young and foolhardy, became intoxicated with the sensation of fl ight and soared ever higher into the sky.

As the wax melted and his feathers dropped away, Icarus fl apped his arms frantically and in vain, plummeting headlong into the sea and drowning.

41

Fortunately, builders today have the option of the Ozone Panel

for protection from the hot sun. Because the Ozone Panel uses

Polyisocyanurate, a Thermoset foam specifi cally designed not to

lose its integrity even under bushfi re conditions. Which makes it

the ideal roofi ng material under the Australian sun.

Section

5ROOF

5Section

DETAIL – ROOF


Plasterboard

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5Section

DETAIL – ROOF

Detail 5.2 Connection Between Rood and Wall – Square Cut Eave

Ozone Panel

Plasterboard

Ozone Panel

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5Section

DETAIL – ROOF

Detail 5.3 Connection Between Rood and Wall – Vertical Eave

Plasterboard

Ozone Panel

Ozone Panel

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5Section

DETAIL – ROOF

Detail 5.4 Pre-Engineered Wood Trusses

Ozone Panel

Plasterboard

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5Section

DETAIL – ROOF

Detail 5.5 Ridge Connection

Ozone Panel

Plasterboard

Ozone Panel

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5Section

DETAIL – ROOF


Ozone Panel

Plasterboard

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5Section

DETAIL – ROOF


Plasterboard

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5Section

DETAIL – ROOF


Section

Plasterboard

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5Section

DETAIL – ROOF

Detail 5.9 Valley Connection

Plasterboard

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5Section

DETAIL – ROOF

Detail 5.10 Ozone Panel Connection on Rafter

Plasterboard

Plasterboard

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52

‘God is in the details.’ Mies van der Rohe

RALS

Section

6

53

6Section

DETAIL – PERIPHERALS

Detail 6.1 Rubber

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6Section


6.2 Sealant

Ozone Panel

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6Section


Detail 6.3 Floor Sheathing

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6Section


6.4 Thermal Insulation

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6Section


Detail 6.5 Hydro Insulation

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6Section


6.6 Hydro Insulation

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6Section


Detail 6.7 Acoustic Elements

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6Section


6.8 Fire Protection

Plasterboard

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6Section


Detail 6.9 Fire Traps

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6Section


6.10 Fire Place

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6Section


Detail 6.11 Fire Protection

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65

OZONE PANEL

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UCTS

Section

7

67

Ozone Panels can be supplied with pre-fi tted conduits for electricity or data cabling. Other services can be easily incorporated into the panel.

7Section

DETAIL – DUCTS

Detail 7.1 Ducts

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Codemark Certifi cation

8Section

CODEMARK™ CERTIFICATIONozonepanel.com 69

CODEMARK™CERTIFICATION

8Section

CODEMARK™ CERTIFICATIONozonepanel.com70

CertMark Australasia CodeMark

Assessment Brief’ For THE OZONE

PANEL BUILDING SYSTEM

CERTIFICATE HOLDER

Ozone Panel Pty Ltd Level 31 367 Collins St

Certifi cate Number: CMA-CMAB-40029

PURPOSE

Ozone Panels are load bearing precast panels made up of two facades of OSB3 composite sourced from organically grown tree roots and forest off-cuts (FSC certifi ed) bonded to Polyisocyanurate foam.

TECHNICAL OPINION Building Code of Australia

In the opinion of CertMark Australasia Pty Ltd (CMA),

Notes:

i) The inclusion of the reference to the BCA is aimed at assisting those involved in the design; specifying and building approval/permit process relate the Appraisal to the relevant Performance Requirements of the BCA.

ii) Any changes made to the BCA will be reviewed during the term of validity of this CodeMark Assessment Brief and, where necessary, any amendment required will be published.

THIS ASSESSMENT BRIEF RELATES ONLY TO CODEMARK Certifi cate # CMA-CM40029

8Section


RELATED INFORMATION VALIDITY OF THE OPINION

CONDITION: This CodeMark Assessment Brief applies only to Exsulite™ Thermal Facade System.

WITHDRAWAL: The CodeMark Assessment Brief will be withdrawn or amended if CMA considers that a change in design or manufacturing quality renders the basis of the appraisal invalid, or if reported fi eld experience convinces CMA of unsatisfactory quality or performance.

TERM OF VALIDITY: This CodeMark Assessment Brief will lapse three years after the date of issue unless revalidation has been requested and granted.

RELEVANT DOCUMENTS

1. Australian Buildings Code Board, Building Code of Australia.

2. Reverent Australian Standards.

3. Relevant International Standards.

ASSESSMENT BRIEF OPINION EXTRACT

The Ozone Panel System will satisfy the performance requirements of the BCA as detailed on CodeMark Certifi cate # 40029

1. BCA Volume One: C1.1 and specifi cation C.1.1 SA C1.1 (a) (v) for external walls to FRL of 60/60/60.

2. BCA Volume One: J1.5, (a), (b) to R Values (Energy Effi ciency). 90mm thick panel =R 3.06 120mm thick panel = R 3.99.

3. BCA Volume One: J1.2 (a) as applicable to (Weatherproofi ng).

4. BCA Volume One: FP1.4 as applicable to (Damp and Weatherproofi ng).

5. BCA Volume Two: P2.1 (a), (b) and (c) (Structural Performance to wind rating C4).

6. BCA Volume Two: P2.2.2 (Weatherproofi ng).

7. BCA Volume Two: P2.6.1 (Energy Effi ciency). (and as amended by State and territory variation for VIC).

8. BCA Volume Two: P2.1 and P2.2.2 (wall Cladding).

9. BCA Volume Two: 3.7.4 Bushfi re Areas (BAL40) (External walls). (and as amended by State and territory variation for NSW, SA, Qld& Tas).

10. BCA Volume Two: Part 3.8.6 “Sound insulation” (and as amended by State and territory variation for NT).

11. BCA Volume Two: 3.12.1.1 (a) as applicable to (Energy Effi ciency).

12. BCA Volume Two: 3.12.1.4 (a) External walls.

APPRAISAL BACKGROUND

The Ozone panel System is currently being used for construction of entire house frames (walls, roofs, fl oors) in Europe. Even though Structurally Insulated Panels (SIPs) have been used in USA for over sixty years, there are no internationally recognised building standards that specifi cally apply to SIP panels.

To facilitate the evaluation of this product CMA has relied upon the scientifi c testing and or evaluations carried out by the following professional organisations:

• VIPAC Engineers and scientist, Melbourne Australia.

• Bligh Tanner Consulting Engineers, Brisbane Australia.

• Exova-Warringtonfi re, Dandenong Victoria.

• European Organisation for Technical Approvals ETAG 019 (2004) “Prefabricated Wood-based Load-bearing Stressed Skin Panels.

• NTA SIP Design Guide 2009 – NTA is a national USA 3rd party accreditation company.

• Eurocode 5: Design of Timber Structures includes fastener capacities in OSB boards.

• European Organisation for Technical Approvals TR019 (2005).

• Various British Board of Agreement certifi cations for similar panels (OSB 3 facings and polyurethane core). The Eggers OSB/3 board also has British Board of Agreement (BBA) certifi cation

It is also noted that the OSB bracing board used in the Ozone Panel System as supplied by Eggers has been marketed and supplied by Hyne Australia as OS’Brace, and has been

8Section


available in Australia and certifi ed as complying with the performance requirements of the BCA.

The Ozone panel System is currently being used for construction of entire house frames (walls, roofs, fl oors) in Europe. Even though Structurally Insulated Panels (SIPs) have been used in USA for over sixty years, there are no internationally recognised building standards that specifi cally apply to SIP panels.

To facilitate the evaluation of this product CMA has relied upon the scientifi c testing and or evaluations carried out by the following professional organisations:

• VIPAC Engineers and scientist, Melbourne Australia.

• Bligh Tanner Consulting Engineers, Brisbane Australia.

• Exova-Warringtonfi re, Dandenong Victoria.

• European Organisation for Technical Approvals ETAG 019 (2004) “Prefabricated Wood-based Load-bearing Stressed Skin Panels.

• NTA SIP Design Guide 2009 – NTA is a national USA 3rd party accreditation company.

• Eurocode 5: Design of Timber Structures includes fastener capacities in OSB boards.

• European Organisation for Technical Approvals TR019 (2005).

• Various British Board of Agrément certifi cations for similar panels (OSB 3 facings and polyurethane core). The Eggers OSB/3 board also has British Board of Agrément (BBA) certifi cation

It is also noted that the OSB bracing board used in the Ozone Panel System as supplied by Eggers has been marketed and supplied by Hyne Australia as OS’Brace, and has been available in Australia and certifi ed as complying with the performance requirements of the BCA.

1 GENERAL

1.1 Ozone panels consist of a rigid Polyisocyanurate (PIR) foam core which has been bonded to15mm OSB (oriented strand board) boards mounted each side to form a sandwich panel.

The core and OSB face boards

1.2 Are formed to create a composite insulated structural ‘sandwich’ panel.

This sandwich panel is designed to be able to resist combinations of axial and bending forces.

1.3 The panel core is rebated during manufacture in the factory to take timber top and bottom plates and vertical ‘splines’ which enable the panels to be simply fi tted together on the construction site during site. This form of construction also allows for the transmission of live and dead loads between levels of framing/support.

The panels are 1200mm wide and up to 3m high (general maximum panel height is 2.8m).

8Section


1.4 EUROSTRANDR OSB The outer OSB board used in construction of the Ozone panel is “EUROSTRANDR OSB” This is a is a fl at hardboard with a three-layer structure of oriented distributed strands (micro-veneers) according to DIN EN 300. The special strand geometry (length up to 160 mm) has a high degree of strand orientation in the grain direction of the outer layer which assures outstanding technical characteristics and very good inherent stability. EUROSTRANDR OSB boards for use in humid conditions are made with 100% formaldehyde-free adhesives.

Raw material used in the OSB Board is:• Debarked softwood from domestic forestry• Paraffi n wax emulsion• PU resin• Water

1.5 STRUCTURAL-PHYSICAL CALCULATION VALUESEUROSTRANDR OSB 3 E0 according to EN 300:2006

Characteristic Standard Unit OSB3

Raw density EN 323 kg/m3 ≥ 600

μ-value EN ISO 12572 - 200

Thermal conductivity λR

EN 13986 W/(mK) 0.13

Specifi c thermal capacity c

DIN 4108-4 J/(kgK) 1,700

Reaction to fi re EN 13986 - (≥ 9 mm) D-s2, d0

24h thickness swelling

EN 317 % ≥ 15

Linear expansion per 1 % change of moisture content

EN 318 %/% 0.03

Formaldehyde emission

EN 717-1 PPM < 0.03

1.6 The Polyisocyanurate (PIR) used injected into the core is manufactured by Bayer Germany. The Bayer (PIR) one-step process to produce natural-oil polyols (NOPs) this product has been tailored specifi cally for the construction of the Ozone Panel system.

1.7 The use of PIR in the Ozone Panel is an important future in that it imparts properties which are vital to the overall performance of the fi nishes Ozone panel.

Stresses from positive and negative wind loads, air pressure imbalances are effi ciently transferred from the OSB panels to through the foam core creating a robust composite structure.

2 BASIC CONSTRUCTIONS

2.1 The Ozone panels are manufactured as 90mm and 120mm thick.

2.2 External load bearing walls are required to be 120mm thick to have suffi cient capacity to take combined axial and bending forces.

2.3 Internal load bearing walls may be 90mm thick depending on load and height.

2.4 connected and strengthened with a variety of combinations of timber top and bottom plates and timber (or steel) or special Ozone panel vertical ‘splines’.

2.5 Ozone splines: Ozone splines consist of 90mm wide lengths of Ozone Panel of thickness to fi t inside the rebated panels and enable nail connection. The use of timber vertical ‘splines’ at panel joints serves to enhances the panel load capacity, particularly for taller walls where horizontal joints in the panel may be required.

8Section


3 BENEFITS

The Ozone Panel Construction System provides the following benefi ts:

3.1 The Ozone Panel system is a load bearing precast panel that can be used for exterior structural walls, fl oors, roofs and interior walls.

3.2 An Ozone Panel is comprised of FSC certifi ed OSB3 board made by Egger and a unique structural Polyisocyanurate (PIR) foam.

3.3 A 120mm Ozone Panel has an R-rating of 4.0, meets acoustic requirements for party-walls.

3.4 Ozone panel has a 60/60/60 fi re rating using a single sheet of 16mm Boral Firestop™.

3.5 Ozone panel has and a C4 cyclone rating.

3.6 The specially formulated Polyisocyanurate (PIR) virtually eliminates the risk of mould and bacterial growth thanks to its ability to repel water and vapour.

3.7 The Ozone panels are also fi bre free, so there’s no risk from airborne contamination.

3.8 Engineered joints give excellent air tightness for further protection. Lengths of up to 18m give you more fl exibility in design and can speed up construction.

3.9 The Core of the Ozone panels provides fi re resistance of up to 1 hour. When exposed to fl ame, given that the PIR forms a strong, carbonaceous char that protects the core foam from ignition.

3.10 Ozone Panels are manufactured from a mixture of two principal liquid components and a number of additives to produce highly cross-linked polymers with a 90% closed cell structure providing an excellent resistance to moisture penetration.

3.11 can be erected on any fl ooring system, giving you unlimited design possibilities, while saving the usable area.

3.12 Any changes can be made to existing properties: extra rooms or fl oors, attic, within a short time to reach the fi nal desired result.

3.13 Ozone Panel constructions are certifi ed for 60 years lifespan, while the concrete buildings have a scientifi c lifespan of 50 years.

3.14 The basic Ozone Panel construction cost is 30% less than conventional concrete buildings.

3.15 Exact construction planned costs and precise quantity of materials needed, as on site cutting and fabrication are eliminated.

3.16 Factory prefabrication to exacting ISO9001 quality standards ensures a high quality product conforming to the National Construction Code.

3.17 Low cost modifi cations and fast rate of construction, which will minimise the time, cost and labour.

3.18 Major running and maintenance cost savings over the lifetime of the building, therefore extremely low costs on energy, repairs or design changes.

3.19 The Ozone Panel wall is load-bearing and pre insulated, meaning the weatherproof, structural shell is completed much quicker than traditional methods of construction.

3.20 Erection times are known in advance, therefore Ozone Panel technology offers an accurate delivery date of your turn-key building.

4 BUILDING CODE OF AUSTRALIA COMPLIANCE

4.1 BCA volume Two Part 2.1 P2.1Structural Stability and Resistance to Actions

The Ozone Structural Insulated Panel (Ozone SIP) system is intended as an alternative solution to the Building Code of Australia (BCA), Deemed to Comply Timber Framing design as specifi ed in Part 3.4.3 of the BCA – Volume 2 for Class 1 and 10 buildings.

4.2 For the purposes of CodeMark certifi cation the Ozone Panel System is limited to wall framing as an alternative to the timber wall framing as described in the Australian Standard AS1684 – Residential Timber Framed Construction.

4.3 When fabricated, designed and constructed in accordance with the limitations as specifi ed in this Assessment Brief, the Ozone Panel System is deemed to comply with the Performance Requirements of P2.1 of BCA - Volume 2.

4.4 Tests conducted by Vipac Engineers and Scientists a NATA accredited testing facility have demonstrated that the Ozone Wall Panel System is capable of:

1. Supporting permanent and imposed loads in with AS1170.1,

8Section


2. Withstanding wind loads in accordance withAS1170.2 3.Supporting snow and ice actions in accordance with AS1170.3 and: 4.earthquake loads in Accordance with AS1170.4.

4.5 Additionally the Ozone panels provide an integral bracing capacity, replacing the need for applied bracing sheets as is typically used in timber framed construction.

5 FIRE PERFORMANCE

5.1 The International Building Code requires specifi c fi re performance characteristics for foamed plastics used in building construction, and that they are tested in accordance with ASTM E84 “Standard Test Method for Surface Burning Characteristics of Building Materials.”

5.2 Ozone Panel system has been tested by -Exova-Warringtonfi re, Dandenong Victoria in accordance with AS1530.4 and achieved a FRL of 60/60/60.

5.3 In the opinion of Bligh Tanner Engineers the Ozone Panels System will perform similarly to a stud wall constructed in accordance with the requirements of AS1684 Residential Timber Framed Construction.

5.4 The Ozone Panels System has demonstrated Attack Levels BAL 40 with the necessity for non-combustible cladding in accordance with AS3959 – Construction of Buildings in Bushfi re-Prone Areas.

6 DURABILITY

6.1 The OSB/3 facing boards require protection from weather with a complete weatherproof Cladding system similarly to a timber stud frame.

6.2 The boards are designed for Service to Class 2 of section 2 .03 wood-based panels of in accordance with Eurocode 5. Eurocode 5 covers the design of timber buildings and civil engineering works. Relevant standards referenced under section 2.03 are:• IS EN 300: Oriented Strand Board (OSB) -Defi nition, classifi cation and specifi cations

• IS EN 312-4: Particleboards - Specifi cations - Part 4


• IS EN 312-6: Particleboards -Specifi cations - Part 6


• IS EN 622-2: Fibreboards - Specifi cations - Part 2




• IS EN 636-1: Plywood - Specifi cations - Part 1

• IS EN 636-2: Plywood - Specifi cations - Part 2

• IS EN 636-3: Plywood — Specifi cations - Part 3

• IS EN 12369-1: Wood-based panels - Part 1

• IS EN 12369-2: Wood-based panels - Part 2

• IS EN 12871: Wood-based panels - Performance

• IS EN 13986: Wood-based panels - Characteristics

• IS EN 14374: Structural laminated veneer lumber - requirements

7 THE OZONE PANEL STRUCTURAL SYSTEM

7.1 The Ozone Panel transfer vertical loads through axial compression (or tension in the case of resultant wind uplift) in the OSB facing boards.

The OSB resistance to buckling is greatly enhanced by the bending stiffness of the overall composite action of the fabricated panels.

7.2 Vertical load is transferred into and out of the panels via the nailed connection of the top and Bottom plates.

7.3 Test loading has shown that the panels have very high ultimate strength in compression (VIPAC loaded the 120mm panels up to 100kN/m length without failure), however this capacity in part relies on even bearing of the OSB sheets on the supporting surface.

7.4 To account for tolerance in construction, the load charts that are included in this Assessment brief conservatively rely on vertical load transfer via shear in the nails that connect the OSB to the plates.

7.5 Horizontal wind loads are transferred to top and bottom plates via bending action in the panels. The OSB facings act as fl anges resisting compressive and tensile forces induced by bending action.

7.6 Shear is transferred through the OSB and PIR core. The design model that is used to derive the Design Charts,

8Section


accounts for reduced bending stiffness due to shear deformation in the panel and is calibrated with the defl ection results from the VIPAC testing.

7.7 The combined bending and axial design charts are derived with an axial load eccentricity of panel thickness/4.

7.8 The capacity of the panel system to resist the combined vertical and horizontal loads may be increased by inclusion of timber studs/posts at panel joints (1200cts). The capacity of these additional members (and combined system capacity) may be determined in accordance with AS1720 Timber Structures.

7.9 Situations that may require additional vertical studs include at concentrated loads, beside openings, tall walls, high wind areas and the lower storey of two storey buildings.

7.10 Loads over openings must be supported by lintels housed into the Ozone panels in a similar fashion to conventional timber framing in accordance with AS1684. Lintels shall be designed in accordance with AS1720.

7.11 The Ozone panels provide resistance to horizontal racking forces, in a direction parallel.

7.12 Loads are transferred into and out of the OSB boards via the nail fastening to top and bottom plates. The bottom plates are bolted to the supporting structure. At this stage, the minimum length of individual bracing panels used to determine design capacity is 2.4m (2 panel length) as this is the system that has been tested

8 LOAD BEARING

8.1 Bligh Tanner Engineers have calculated the Load bearing capacity of the Ozone Panel System Based on the following two principal factors:

1. Maximum allowable compressive stress in the OSB facings induced from the combination of axial and bending forces. 2. Maximum capacity of nail fastening of the OSB facings to the top and bottom plates.

8.2 Serviceability defl ections under wind load have also been checked by Bligh Tanner Engineers in accordance with values recommended in AS1684 Residential Framing Code

8.3 The Design Charts are based on the following construction system:

• 63mm deep LVL top plate (or 45x90mm mgp12 ribbon plate)

• 45mm deep LVL (or mgp12) bottom plate

• OSB vertical splines at 1200 cts

• Full height panels without horizontal joins

• Maximum eccentricity of vertical loads of panel thickness/4 (fl oor and roof loads must be supported on to the wall top plates, not off the OSB facing).

9 THERMAL

9.1 The Ozone Panel System has achieves a Thermal resistance commensurate with the panel sizes as tested by Vipac and represented in the graphs below.

8Section


10 TERMITE RESISTANCE

10.1 Ozone panel for the Australian market will be constructed using the Hyne OS’ Brace H2 Blue or similar.

This product is treated to H2 in conformity with AS3660.1 and conform to the termite management requirements of the NCC sections:

10.2 The use of Termite resistant or treated materials in a building does not negate the need for the builder to adequately address the provisions for termite control as detailed in AS3660.1 -2000.

11 ACOUSTIC PERFORMANCE

11.1 Acoustic performance is the measurement of airborne Sound Reduction Indices (R) of sample wall system in accordance with AS1191-2002 Acoustics – Method for Laboratory Measurement of Airborne Sound Transmission Loss of Building Elements. Assessment Brief of Weighted Sound Reduction Indices ( R w ) and Spectrum Adaption Terms (C tr) in accordance with AS/NZS ISO 717.1.2004: Acoustics – Rating of sound insulation in buildings and of building elements – Airborne sound insulation

The Ozone Panel System signifi cantly improves acoustic performance. Its construction actively dampens noise and reduces the sound waves entering, or exiting the home.

12. FIRE

12.1 The Ozone Panel System has been tested by Exova-Warringtonfi re, Dandenong Victoria. and achieved the following results:

• FRL 60/60/60

• BAL 40.

BAL 40 (Very High Risk areas) Increasing levels of ember attack and burning debris ignited by windborne embers together with increasing heat fl ux with the increased likelihood of exposure to fl ames.

13 BASES OF THE ASSESSMENT BRIEF

13.1 CMA CodeMark Assessment Brief has assessed the following aspects in undertaking the Certifi cation:

(a) Installation procedures (b) Physical Properties (c) Relation to relevant BCA clauses (d) The ability of the installation details to meet the requirements of the BCA and relevant Australian and international standards.

13.2 Note:

The validity of Ozone Panel system as conforming to the Performance Requirements of the BCA is dependent on the following limitations and qualifi cations:

8Section


(1) That Designs incorporating Ozone panels as an alternative to timber framing in accordance with AS1684 must be certifi ed by a Registered Professional Engineer.

(2) The Quality Control procedures of the Ozone Panel fabrication and production of PIR and OSB components will be audited and monitored by CMA in accordance with the design freeze, the Scheme of Testing and Inspection (STI) and the Third Party Certifi cation Agreement.

(3) Construction utilising Ozone panels must be in accordance with the Installation Ozone System Installation Manual (Version 1 2012) and only be done by qualifi ed installers.

The Ozone panels must not be unduly exposed to moisture during construction.

14 MANUFACTURERS’ AND INSTALLATION INFORMATION

-Ozone System Installation Manual (Version 1 2012). -Technical Construction drawings supplied by Ozone panel -Technical data sheets and laboratory results supplied by Vipac A NATA accredited testing facility. - Hyne OS Brace H2 technical information.

15 TEST REPORTS

-Various VIPAC Engineers and scientist, Melbourne Australia. -Bligh Tanner Consulting Engineers, Brisbane Australia. -Exova-Warringtonfi re, Dandenong Victoria.

16 OTHER DOCUMENTS

1. Ozone System Installation Manual (Version 1 2012).

2. European Organisation for Technical Approvals ETAG 019 (2004) “Prefabricated Wood based Load-bearing Stressed Skin Panels

3. NTA SIP Design Guide 2009 – NTA is a national USA 3rd party accreditation company

4. SBS SIP Building Systems has British Board of Agrément (BBA) certifi cation for similar panels (OSB 3 facings and polyurethane core) which it produces in the UK for the European market.

5. Eurocode 5: Design of Timber Structures includes fastener capacities in OSB boards.

6. Eggers OSB bracing board technical sheets.

Hyne as OS’Brace, available in Australia and certifi ed as complying with the performance requirements of the BCA. Technical literature for the 6mm panel includes bracing and uplift capacities achieved through nailing of the boards to a timber stud frame. These values are useful for confi rmation of capacities derived for the 15mm OSB faced Ozone panels. The Eggers OSB/3 board also has British Board of Agreement (BBA) certifi cation

INSPECTIONS:

CMA Assessment Brief representatives have inspected installations of the systems and found the level of performance satisfactory.

ENVIRONMENTALLY STATEMENT:

Given that the construction industry is a signifi cant contributor to greenhouse gases any innovative product that can assist in

8Section


the reduction of C02 in the environment must be considered a Future Friendly Product.

Cement production alone accounts for fi ve per cent of all global carbon dioxide emissions – that is more than the entire aviation industry. Regrettably the long-term trends in the use of Cement are increasing exponentially: it is estimated that by 2020 the demand for cement will increase by as much as 50 per cent.

The OSB board used in the Ozone panel system binds approximately 864 kg CO2 per M3 (calculation based on GWP 100 production) This corresponds to the average CO2 emissions for a mid-size car over a distance of 6,647 km. 65% of the materials used in Ozone Panel can be used again after lifespan period, compared to 25% on concrete, 35% on steel structure and 65% on conventional timber frame

There is no “heavy” industry production for iron, cement, aggregates, bricks etc. needed

The materials used in the manufacture of the Ozone panels comes from one source only, as an integrated building system, therefore there is less impact on the environment.

There is less air & water pollution, gas emission, CO2 emission compared to other systems (concrete, bricks, steel) on the construction stage as well as on the running period of the building (due to the energy effi ciency and air tightness).

The Ozone panel Company has been audited by CMA as compliant with ISO14001 Environmental Management and has been certifi ed a: Future Friendly Company.

CODEMARK CERTIFICATION:

CodeMark is a building product certifi cation scheme. The CodeMark scheme supports the use of new and innovative building products by providing a nationally and internationally accepted process for products to be assessed for compliance with the requirements of the building codes of Australia and New Zealand. The scheme provides confi dence and certainty to regulatory authorities and the market through the issue of a Certifi cate of Conformity.

The ABCB and New Zealand’s Department of Building and Housing (DBH) manage the scheme in their respective countries. The Joint Accreditation System of Australia and New Zealand (JAS-ANZ) have accredited CertMark to evaluate and certify building products. Relevant legislation requires building control authorities to accept CodeMark certifi ed products.

Date: 14/12/12

John Thorpe

Director CertMark Australasia Pty Ltd

MATERIAL SAFETY DATA SHEETozonepanel.com80

Issue Date: JULY 2012

OZONE PANELS

1. IDENTIFICATION OF THE MATERIAL AND SUPPLIER

PRODUCT NAME: Polyisocyanurate (PIR) Foam

SYNONYM: Erathane Polyisocyanurate Foam, Resifoam Polyisocyanurate Foam

USE: Polyisocyanurate (PIR) foam can be used in a variety of applications, particularly where good fi re-resistant properties are required.

Ozone Panel Pty Ltd

Level 31367 Collins StreetMELBOURNE, VIC 3000AUSTRALIAPh: +61 4 38172005Fax: +61 3 9629 5226

Emergency Advice All Hours:Technical Manager: +61 4 38172005

2. HAZARDS IDENTIFICATION

NOT CLASSIFIED AS HAZARDOUS ACCORDING TO NOHSC CRITERIA

HAZARD CATEGORY: None allocated

HAZARD CLASSIFICATION: NON-HAZARDOUS SUBSTANCE, NON-DANGEROUS GOOD

RISK PHASES: None allocated.

SAFETY PHASES: None allocated.

POISON SCHEDULE: None allocated [Aust].

WARNING STATEMENT: Non-hazardous substance with recommended use. Fully cured PIR foams present no health hazard; they are chemically inert and insoluble in water and most organic solvents.

If the PIR foam is changed chemically by burning or heating the material to a decomposition temperature, then potentially hazardous fumes/vapours may be produced rom the foam.

3. COMPOSITION / INFORMATION ON INGREDIENTS

SUBSTANCE NAME PROPORTION CAS NUMBERPolyisocyanurate (PIR) Solid 98-100% MixtureMineralised Glass Tissue 0-2 % Not Applicable

4. FIRST AID MEASURES

SWALLOWED: If swallowed, do no induce vomiting. No adverse effects anticipated by this route of exposure, incidental to proper industrial handling.

EYE: If mechanical cutting or grinding of the PIR foam produces dust that enters the eyes, fl ush with plenty of water for at least 15 minutes, ensuring eye lids are held open. If irritation develops or persists, seek medical attention.

SKIN: If dust from mechanical cutting or grinding of foam falls onto the skin, remove any contaminated clothing and wash skin thoroughly with water and soap. If irritation develops or persists seek medical attention.

INHALED: No vapours produced with usual industrial handling as the PIR foam is an inert solid. If the PIR foam is chemically changed by burning or heating then vapours will be produced. In this case, increase ventilation or move exposed person to fresh air. Apply resuscitation if victim is not breathing. If trained personnel available administer oxygen if breathing is diffi cult. If symptoms develop, seek medical attention. Our product does not contain any fi bres of a diameter less than 3 microns and with lengths between 5 and 100 microns. They are therefore not respiratable.

FIRST AID FACILITIES: Eye wash fountain, safety shower and normal wash room facilities.

ADVICE TO DOCTOR: Treat symptomatically.

In case of poisoning, contact Poisons Information CentreIn Australia call Tel: 131126In New Zealand Tel: 034747000

MATERIAL SAFETY DATA SHEETozonepanel.com 81

5. FIRE-FIGHTING MEASURES

FIRE/EXPLOSION HAZARD:If safe to do so, move undamaged material from fi re area.

HAZARDOUS DECOMPOSITION PRODUCTS: Decomposes on heating emitting soot, smoke, gaseous hydrocarbons, oxides of carbon and nitrogen, hydrogen cyanide and hydrogen chloride.

FIRE FIGHTING PROCEDURES: Fire fi ghters to wear Self-Contained Breathing Apparatus (SCBA) in confi ned spaces, in oxygen defi cient atmospheres or if exposed to products of decomposition. Full protective clothing is also recommended.

EXTINGUISHING MEDIA: Use extinguishing media suitable for surrounding fi re situation. E.g. water spray, carbon dioxide, dry chemical powder or appropriate foam.

HAZCHEM CODE: None allocated [Aust]

FLAMMABILITY: PIR solid is not fl ammable. Toxic and/or irritating fumes/vapours may be emitted under fi re conditions by chemically burning or heating material to decomposition temperatures.

6. ACCIDENTAL RELEASE MEASURES

If mechanically cutting or grinding the PIR foam, dust or particulate matter will be generated, which can be swept up and disposed of by wrapping in an appropriate container and then discarding to landfi ll in accordance with all regulations. Spilled dust may present a slipping hazard.

If fi re conditions prevail and the PIR foam begins to burn ventilate area as toxic vapours are produced. Keep unnecessary people away. Isolate hazard and deny entry. Stay upwind. If possible wet area down to prevent high dust levels. Use dustless methods, including a HEPA fi lter and vacuum, and place into a suitably labelled and sealable container for later disposal. Do not dry sweep. Wear protective equipment as outlined in Section 8 of this Material Safety Data Sheet.

7. HANDLING AND STORAGE

PIR foam with proper industrial handling at ambient temperatures requires no special measures. We recommend keeping the material away from sources that would cause the foam to burn. Store away from oxidizing agents, acids and alkalis. When cutting or grinding the PIR foam, dust will be produced so appropriate personal protective equipment (as outlined in Section 8 of this Material Safety Data Sheet) is recommended.

8. EXPOSURE CONTROLS / PERSONAL PROTECTION EXPOSURE STANDARDS

No exposure standards have been assigned by [NOHSC] for this product or any of the components:

POLYURETHANE SOLID: No Exposure details available.

ENGINEERING CONTROLS: PIR foam in its usual state does not require any specifi c engineering controls. If mechanically cutting or grinding the foam, dust will be produced, and dust control measures will be required. Ensure adequate ventilation and provide suitable personal protective equipment such as dust masks.

PERSONAL PROTECTION EQUIPMENT

CLOTHING: Wear suitable protective clothing to prevent dust contact with skin. Lab coat or overalls recommended if cutting or grinding the PIR foam as part of good industrial hygiene practices.

GLOVES: Wear impervious gloves to prevent dust contact with skin as part of good industrial hygiene practices.

EYES: Wear safety glasses with side shields, chemical goggles or face shield if mechanically cutting or grinding the PIR foam.

RESPIRATORY PROTECTION: Respiratory protection only required if PIR foam is heated or burnt. Avoid breathing of vapours when the product is heated or burnt. Avoid breathing dusts when the product is mechanically cut or ground. Select and use respiratory protection in accordance with AS/NZS 1715/1716. Dust mask should be worn when dusts are produced. When fumes/vapours exceed the exposure standards then the use of an atmosphere-supplied, positive pressure demand self-contained or airline breathing apparatus supplied air respirator complying with the requirements of AS/NZS 1715 is recommended. Filter capacity and respirator type depends on exposure levels and type of contaminant. If entering spaces where the airborne concentration of a contaminant is unknown then the use of a Self-contained breathing apparatus (SCBA) with positive pressure air supply complying with AS/NZS 1715 / 1716, or any other acceptable International Standard is recommended.

MATERIAL SAFETY DATA SHEETozonepanel.com82

9. PHYSICAL AND CHEMICAL PROPERTIES

Appearance: Variable depending on product Boiling Point Melting Point: Product is solid.

Vapour Pressure: Not applicable.

Specifi c Gravity: Variable depending on product.

Flash Point: Not applicable.

Flammability Limits: Not applicable.

Solubility in Water: Insoluble.

Other Properties: None determined.

10. STABILITY AND REACTIVITY

STABILITY: Stable under normal conditions of use.

HAZARDOUS DECOMPOSITION PRODUCTS:Emits toxic and/or irritating fumes including gaseous hydrocarbons, oxides of carbon and nitrogen, hydrogen cyanide and hydrogen chloride when heated to decomposition.

HAZARDOUS POLYMERIZATION: Will not occur.

INCOMPATIBILITIES: Strong acids, alkalis, combustibles and oxidizing agents.

CONDITIONS TO AVOID: Heat, fl ames and other ignition sources, to avoid production of toxic vapours from burning.

11. TOXICOLOGICAL INFORMATION

No adverse health effects are expected, if the product is handled in accordance with this Material Safety Data Sheet and the product label. Symptoms and effects that may arise if the product is mishandled and overexposure occurs are:

ACUTE HEALTH EFFECTS: The primary adverse health effects of this material are related to the dust created by cutting or grinding the PIR foam. Mechanical or exhaust ventilation should be provided during this type of activity.

SWALLOWED: Single dose oral toxicity is believed to be very low. No hazards anticipated from swallowing small amounts incidental to normal handling operations. Swallowing of dust may cause mild irritation of mucous membranes in mouth, throat and digestive tract.

EYE: Possible mechanical irritant to the eyes from dust particles.

SKIN: Possible mechanical irritant to the skin from dust particles.

INHALED: Dust may cause irritation to upper respiratory tract. May irritate mucous membranes. At room temperature, no exposure to vapours is likely due to physical properties.

CHRONIC: Product is not expected to have adverse impact on human health.

TOXICOLOGICAL DATA: There is no other toxicological information available for this product.

12. ECOLOGICAL INFORMATION

ECOTOXITY: There is no information available for this product.

MOBILITY: Insoluble in water.

PERSISTENCE / DEGRADABILITY: There is no information available for this product.

CHEMICAL FATE INFORMATION: There is no ecological information available for this product.

13. DISPOSAL CONSIDERATIONS

Dispose of in accordance with all relevant Local, State and Federal regulations. Dispose of material through a licensed waste contractor. Any processing, use, or contamination of this product may change the requirements for disposal. It is the responsibility of the generator of the waste to properly classify, transport and dispose of the waste. The PIR foam and any dust or particles, produced from a cutting or grinding action, are inert and can be placed in landfi ll.

14. TRANSPORT INFORMATION

ROAD TRANSPORT

UN Number: None allocated.

Proper Shipping Name: None allocated.

Dangerous Goods Class: None allocated.

Packing Group: None allocated.

Label: None allocated.

MATERIAL SAFETY DATA SHEETozonepanel.com 83

AIR TRANSPORT






SEA TRANSPORT






15. REGULATORY INFORMATION

POISON SCHEDULE: None allocated [Aust].

16. OTHER INFORMATION

DATE OF PREPARATION:ISSUE DATE:SUPERSEDES: None.REASONS FOR UPDATE: New format.

KEY LEGEND INFORMATION:

NOHSC - National Occupational Health & Safety Commission {Formerly Worksafe}[Aust]

SUSDP - Standard for the Uniform Scheduling of Drugs and Poisons [Aust]

TWA - Time Weighted Average [Int]

STEL - Short Term Exposure Limit [Int]

AICS - Australian Inventory of Chemical Substances

EPA - Environmental Protection Agency [Int]

NIOSH - National Institute for Occupational Safety and Health [US]

AS/NZS 1715 - Selection, use and maintenance of respiratory protective devices. [Aust/NZ]

AS/NZS 1716 - Respiratory protective devices. [Aust/NZ]

IATA - International Aviation Transport Authority [Int]

ICAO - International Civil Aviation Organization [Int]

IMO - International Maritime Organisation. [Int]

IMDG - International Maritime Dangerous Goods [Int]

United Nations Recommendations for the Transport of Dangerous Goods and Globally

Harmonized System for the classifi cation and labelling of Chemicals. [Int]

EU - European Union

[Aust/NZ] = Australian New Zealand

[Int] = International

[US] = United States of America

Removal of the heading of Poison Schedule [Aust], in section 3 and 15 of this Material Safety Data Sheet (MSDS) makes this a valid health and safety document in other international jurisdictions/countries. For full compliance please contact your Federal, State or Local regulators for further information.

DISCLAIMER:This MSDS summarises our best knowledge of the health and safety hazard information available on the product and the measures to be used to handle and use the product safely. Each user should read this MSDS and consider the information in connection with the way the product is intended to be handled or used.

PRINCIPAL REFERENCES:Information supplied by manufacturer, reference sources including the public domain.

©OZONE PANEL PTY LTD OCTOBER 2017

ozonepanel.com

c/- LEVEL 32 – 360 COLLINS STREETMELBOURNEVIC 3000

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