Exsulite Specification & Installation Manual
Contents
1. Site Address C Within 1km of Coastal Area Wind pressures confirmed by engineer Project Builder Contact Number Contact Name AAC Brick Other Ground Level Construction Exsulite AAC Brick Other L Dulux Specification Number Upper Level Construction Exsulite Exsulite Panel Wall Area m Exsulite Trained Installer Entity Company Name Installer Name Exsulite Installer No Mobile Nominated Installer Nominated Installer No Exsulite Trained Finisher Entity Company Name Installer Name Exsulite Installer No Nominated Installer Mobile Nominated Installer No Site Access and Scaffolding Checklist Yes No Comments By Who ls all access scaffolding set up to install the specified system ls all scaffolding and access equipment checked and approved Installer Checklist Yes No Comments By Who All Exsulite components supplied by Dulux with no substitution Checked frame with straight edge up to 5mm tolerance Was rectification required and if so by whom Checked frame for additional back blocking to ensure double studs at vertical butt joints to panels Page 1 of 3 5412 0714 Installer C2. 5412 0714 Exsulite Thermal Facade System by Certificate of Installation The Exsulite Certificate of Installation is for use by a Exsulite Trained amp Registered Installer as a Quality Control Document to certify that the specified Exsulite system has been installed in accordance with the Exsulite Installation procedures as set out in the Exsulite Specification amp Installation manual Exsulite Construction Drawings manual amp Dulux AcraTex specification The Certificate of Installation is used to record on site work procedures amp substrate standards for the Installation of the Exsulite Thermal Facade System and the Application of Dulux AcraTex finishing system signed off amp handed over at job completion The Exsulite Certificate of Installation and Exsulite Warranty Job Registration forms are required for warranty purposes and forms part of the Exsulite warranty procedure The Exsulite Trained Installer and Exsulite Trained Finisher can either be the same or separate entities who have attended the Exsulite Training Course System Used Please tick one Exsulite Thermal Facade Cavity System Exsulite Composite Thermal Facade Cavity System Exsulite Thermal Facade Non Cavity System Exsulite Composite Thermal Facade Non Cavity System ExsuliteKooltherm Thermal Facade System Project Information Project Start Date Timber Frame Steel Frame
3. EXSULITE FACADE SYSTEMS SPECIFICATION amp INSTALLATION MANUAL AUSTRALIA 01 OCTOBER 2014 VERSION 1 SECTION 1 EXSULITE FACADE SYSTEM SPECIFICATION EXSU LI i E dul eL 1 1 1 If you are a Specifier 4 4 5 1 1 2 If you are a Dulux AcraTex Exsulite Trained amp Registered Installer 5 SPECIFIC ATION 1 1 3 If you are a Builder 5 5 Z 1 1 4 Design amp Installation amp INSTALLATION MA 1 3 0 Design Considerations 1 3 1 Design Ultimate Wind Pressures 9 1 3 2 Framing amp Substructure 11 1 3 3 Metal framing must comply with 11 THE SOLUTION 1 3 4 Slab amp Footings 11 1 3 5 Ground Clearance 11 TO LIGHTWEIGHT 1 3 6 Coastal Areas 11 WALL CLADDING 1 3 7 Colour Selection 11 1 3 8 Control Joints 12 SYSTEMS 1 3 9 Fire Resistant Levels FRL 12 1 4 0 System Performance Criteria 1 1 4 1 Exsulite Facade System consists of 14 1 4 2 Moisture Management 14 1 4 3 Exsulite Facade System Composition 15 1 4 4 Impact Resistance A 1 4 5 Water Vapour Resistance WA 1 4 6 Weatherproofing amp Water Resistance IZ 1 4 7 Penetrations 17 1 4 8 Waste Management 17 SECTION 2 EXSULITE FACADE SYSTEM INSTALLATION 18 2 1 0 Dulux AcraTex Exsulite Trained amp Registered Installer 18 2 1 1 Quality Control 18 2 1 2 Handling and Storage 18 2 1 3 Component Checking 18 2 1 4 No Component Substitution 18 2 1 5 Exsulite Facade System Components 19 2 1 6 Exsulite Facade System Material Estimate Guid
4. Panel Type Exsulite EPS Raw Panel 40mm 60mm 75mm 80mm 100mm L Olher Exsulite Composite Panel 40mm 60mm 75mm 80mm 100mm Other Exsulite Kooltherm Panel m Bim Omm Other Exsulite screws and washers installed at maximum 275mm vertically and maximum 600mm horizontally Approved aluminium flashing tape installed around windows doors meter box openings and all penetrations Exsulite panels glued fully along abutting edges with approved foam adhesive All exposed panel edges fully enclosed with PVC channel Exsulite cavity closer with weep holes Exsulite PVC external angles fixed with approved adhesive Control Joints to masonry with 10mm gap and backing rod strip Exsulite panel to window sills cut at minimum 10 degrees Detail at concrete slab rebate in accordance with Exsulite Construction details m All components have been installed fully in accordance with Exsulite Installation Manual and Construction Details Collected all off cuts and placed in clear plastic bags for recycling collection Installer sign off Name Installer No Signature Date of completion Page 2 of 3 5412 0714 Applied PU sealant to expansion joints control joints Comments and around windows meter box and other penetrations 1s NO Do not overcoat sealant with Basecoat or Texture Overcoat only with membrane External PVC angles
5. amp Installation Manual Version 1 O1 October 2014 1 3 1 4 1 Exsulite Facade System consists of Exsulite Breathable Vapour Permeable Wall Wrap e Cavity Spacer H Grade EPS Batten where a cavity is to be installed e Damp proof course Exsulite EPS Panel or Exsulite Composite Panel Exsulite fixing disk amp Class 3 10 gauge bugle head screws further than 1km of coastal areas Exsulite Starter Channel with weep holes placed at the base of the cavity these function as a cavity closer lo drain to the exterior at the bottom of the cavity e Corner angles and expansion beads installed prior to render application e Flashing Tape aluminium bituminous selFadhesive flashing tape for weatherproofing around all window frames including sills doors openings penetrations intersections connections heads and jambs all of which must be flashed prior to panel installation e Dulux Acralex Approved PU expanding foam adhesive Exsulite Matrix levelling coat with a minimum Exsulite 165gsm alkali resistant mesh e Exsulite Acrylic Texture coating to selected colour with a LRV gt 35 Selleys Flexiseal Joint Sealant or as approved by Dulux AcraTex e Exsulite Membrane or Dulux AcraTex AcraShield Advance or AcraSkin weatherproof membrane top coat to selected colour with a LRV gt 35 1 4 2 Moisture Management Cavity System The Exsulite Facade System helps moisture management through its self draining cavity spac
6. Ae External Angles 90 Degrees 23 31 38 A5 54 69 Pi starter trim PVC Weepholes 9 T 13 16 19 21 Expansion Joint PVC Trim 3m x 3 5mm 3 4 5 6 Flashing tape 75mm x 25m roll 2 3 4 5 5 Selleys Liquid Nails Fast 300ml Tube 6 8 10 12 14 18 Foam Adhesive 750ml Canister 4 Z 8 12 Application Gun Metal Gun Cleaner 300ml Canister 2 2 2 NOTE The above calculations are a guide only allowance for wastage should be allowed when determining job quantities The above material estimates are based on a frame with the studs at 600mm centres Exsulite Specification amp Installation Manual Version 1 O1 October 2014 EJ 2 1 7 Tools Requirements kis Electric saw N Safety gloves Hammer Floats plastic amp foam with diamond tip blade fitted with amp sa fety glasses a vacuum extraction appliance where possible Hot Knife Dust mask Hawk amp trowel 9 he Sy Hand saw Mixing drill Portable work bench Staple Gun an gt CO Roller Scaffold Sharp blade knife Caulking gun Spatula 2 1 8 Before Commencing Installation Read the Exsulite Facade System Specification amp Installation Manual in conjunction with the project consultant project specific specification and drawing details to familiarise yourself with the relevant project specific requirements It is the responsibility of the Dulux AcraTe
7. installed and by who Yes No By Who Protective drop sheets to roof and adjacent areas Vas No Date Batch No Quantity bags Exsulite Matrix Basecoat applied a omments Exsulite mesh embedded into basecoat overlapped C Comme min 100mm diagonal strips at corners of openings Yes No Green Render Sealer when texture coating within C Date Comments 5 days of base coat application Yes No Date Batch No Quantity buckets Exsulite Texture coat applied Prod E P roduct olour omments Date Batch No Quantity buckets Exsulite Membrane top coat applied e EE T roduct olour omments Applied in accordance with Dulux AcraTex Exsulite C Commens es o product data sheets and product specifications Finisher sign off Name Installer No Signature Date of completion Project Specific Checklist Item Description Comments By Who Other Comments On completion of this form it is the responsibility of the Exsulite Trained Installer to forward it to Dulux AcraTex by email to sales exsulite com au or by fax to 61 8 8347 1963 as part of job registration process Dulux Acralex is a division of DuluxGroup Australia Pty Ltd ABN 67 000 049 427 Dulux AcraTex and Exsulite are registered trade marks and Matrix Basecoat is a trade mark of DuluxGroup
8. rates nominated are theoretical maximum rates required to achieve the specified film builds for technical performance Exsulite Specification amp Installation Manual Version 1 O1 October 2014 33 2 3 1 Standards Of Finish Permissible Variation Design samples approved by the Contractor Builder are provided as indicative examples only and are not intended as finished examples of onsite application The appearance of the finished system shall as near as practicable match the approved onsite sample in terms of installation details texture colour and uniformity Permissible variation and due regard shall be given for textural variation owing to multiple applicators onsite restraints scaffold limitations and angle or side light or illumination accentuating surface irregularities 2 3 2 Care Precaution The manufacturers recommendations for installation and application as specified in the installation amp application guidelines must be observed at all times The coating system must not be applied when rain is anticipated Adequate protection against rain and dust must be provided for the coating during application During periods of high temperature above 30 C work needs to be scheduled during the coolest part of the day and away from direct sunlight During periods of cooler temperatures 10 18 C work needs to be scheduled during the morning and completed with adequate time to allow the coating to form a coherent film before the t
9. 0mm 25mm R2 0 4 990 3 130 Exsulite Thermal Facade Non Cavity System s R Value R Volue Ponel Thickness Wall Insulation VUL A Z5mm R2 O 4 220 2 380 100mm R2 0 4 890 3 050 The above calculations are in presented in accordance with the principles outlined in the Building Code of Australia 2012 Exsulite RValues are calculated on M Grade EPS to Australian Standard 1366 3 with a conductivity value of 0 0383 W m K Smart Rate Thermal Assessment report SLR Consulting can be provided upon request 1 4 4 Impact Resistance The Exsulite Thermal Facade System provides impact resistance to levels similar to that of other common nom masonry materials Minor damage can be repaired by recoating with Dulux AcraTex coating system Additional impact resistance can be achieved with the additional layers of Exsulite alkali resistant mesh and Exsulite Matrix Basecoat 1 4 5 Water Vapour Resistance Exsulite EPS Panels have one of the highest resistance levels of all materials used for insulation Exsulite EPS Panels have a low water vapour transmission rate however it is not considered as an adequate vapour barrier Exsulite Breathable Vapour barrier Wall Wrap must be installed in all cases irrespective of the buildings environment and location as part of the full Exsulite Facade System 1 4 6 Weatherproofing amp Water Resistance Exsulite Facade System weatherproof finishing Exsulite Membrane AcraTex AcraShiel
10. Australia Pty Lid Kooltherm is a registered trade mark of Kingspan Holdings IRL Limited Page 3 of 3 Exsulite Thermal Fa tem by Thermal Facade System by jpg cra Ee For further information go to www exsulite com au Dulux AcraTex Customer Service 1300 662 841 1 Jeanes Street Beverley SA 5009 Australia Dulux AcraTex is a division of DuluxGroup Australia Pty Ltd ABN 67 000 049 427 Dulux AcraTex Exsulite Selleys Liquid Nails and AcraShield are registered trade marks of DuluxGroup Australia Pty Ltd Acra Bond AcraSkin Green Render Sealer and Matrix Basecoat are trade marks of DuluxGroup Australia Pty Ltd Bradford is a trade mark of CSR Building Products Limited 5710 1014 Exsulite
11. OV La L a ana te tare NO14 SEINO SONINadO JOL SEOIACIV INO 148 O1 October 2014 Exsulite Specification amp Installation Manual Version 1 Refer to the Exsulite Construction Drawings for above roof details 2 2 4 Cavity Spacer for use in a Cavity System Vertically install H Grade EPS battens to each timber stud for residential housing construction using hot dipped galvanised clouts Fix the cavity spacer onto all studs and around all windows amp doors and ensure that it is finished hard down on the inside edge of the Exsulite starter channel Once all cavity spacers are installed on each elevation or wall side check with a straight edge to ensure the wall is level to within a 5mm tolerance over a 3 metre span The panel is fixed to the vertical batten cavity spacer to allow for drainage to the cavity closer starter channel at the base of the wall 2 2 5 Exsulite EPS Panel amp Composite Panel Fixing Measure and cut Exsulite panels using a masonry diamond blade in a standard power saw or a sharp knife The panel to be installed oriented horizontally with a staggered brick joint layout and fixed at 275mm centres on stud lines Exsulite fixings are to be used in all cases with no substitution allowed of non approved alternative fixings Fixings should be started at 50mm from the bottom of the first sheet at ground level Typically 5 fixings are used per stud line subject to wind classification The panel is
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13. allation Manual is intended for use by Dulux AcraTex Exsulite Trained amp Registered Installers builders specifiers and designers who are involved with the specification amp installation of the Exsulite Facade System Providing more design flexibility options and faster build process than conventional masonry construction 1 1 0 Overview Dulux AcraTex is a pioneer in the use of External Insulation Facade Systems EIFS designing and installing coating systems specifically for wall applications EIFS walling systems have been used in Europe for over 50 years In recent years the use of Lightweight Cladding Systems as alternate solutions in the building and constructions industry has grown rapidly but proper system design and installation has not been considered The Building Code of Australia BCA or National Construction Code NCC requires appropriate design and installation controls to qualify any alternate solution and ultimate success requires a total system approach integrating design componentry installation and performance requirements The Exsulite Facade System by Dulux AcraTex protects specifiers surveyors builders and their clients from the risks of mixed componentry being used with uncontrolled installation Exsulite Facade System by Dulux Acralex offers a single supply source for the Total Light Weight Facade System from wall wrap to the weatherproofing coating The Exsulite Facade System is a light weight ext
14. alled Articulation Joints AJ make the walls more flexible by breaking it into a serious of small areas Differential movement between the facade and adjacent structural elements need to be accommodated for via an A J joint Control Joints C J is an expansion joint to relieve thermal expansion or contraction between the Exsulite Facade System and other adjacent building substrate or structures Good building practice provides for expansion joints at 3m max height amp 6m max wide intervals and at all building weak points or where potential cracking may occur e g in line with openings windows doors horizontally between floor levels and at all interfaces of different building construction materials and or as defined by a responsible Building Project Engineer The placement and correct installation of control joints is the responsibility of the Building Engineer Builder in determining the placement and number of control joints to accommodate any anticipated movement Typical vertical control joints and horizontal joints filled with a suitable backing rod and approved flexible polyurethane sealant The project engineer has responsibility for determining where control joins are to be located 1 3 9 Fire Resistant Levels FRL amp Bush Fire Attack Levels BAL BCA Vol 2 Part 3 7 1 details the requirements in residential buildings for fire resistance for external walls where the external wall is less than 0 9m from an allo
15. anent repairs undertaken During your inspections don t forget to check areas that are cold and dark such as behind heavy foliage Dirt provides the perfect nutrient for mould and algae growth The tiny roots that these organisms use to cling to your walls will cause your texture coating to deteriorate very quickly if not regularly cleaned Recoating is recommended after a minimum of 10 years to rejuvenate the surface appearance This can be done by using Dulux AcraTex AcraSkin protective membrane coating to a selected Dulux AcraTex colour which will protect from air pollutants water ingress and dirt accumulation to provide a new low maintenance surface Exsulite Specification amp Installation Manual Version 1 O1 October 2014 35 2 4 1 Health amp Safety Dulux Acralex recommends safe work practices at all times including the use of personal protective equipment face mask safety goggles safety shoes Fine dust cuttings can be hazardous and personal protection equipment is recommended at all times All cutting should be conducted in well ventilated spaces Power tools should be up to date with test amp tagged label in accordance with state OH amp S regulations and should be fitted with dust extraction systems Refer to your local WorkCover or WorkSafe authority websites for your local OH amp S regulations prior to commencement of work For all product handling procedures refer to the relevant product MSDS prior to work commenci
16. ass 4 screws must be used This is deemed as medium to severe marine exposure in accordance with AS 3566 Exsulite fixings Class 3 non coastal areas 10 Gauge screws with an Exsulite 40mm fixing disk is driven into the middle of the stud until the disk just penetrates the panel face When fastened correctly the screw head and the 40mm fixing disk should be slightly countersunk in a concave recess on the outer surface of the panel and located so as it retains its original shape NOTE Care should be taken to not overdrive the fixing as this will strip the plastic disc and the fixing will be ineffective General vertical fixing spacings of 275mm 5 fixings at 275mm spacing 25 per sheet with 50mm end distance at panel corner adds up to 1200mm panel width with stud spacings at 600mm maximum and subject to panel span and thickness Exsulite Specification amp Installation Manual Version 1 O1 October 2014 ES 2 2 0 Installation Procedure 2 2 1 Exsulite Wall Wrap Install the Exsulite Breathable Wall Wrap with a staple gun to a properly prepared frame Appropriate head flashings over the top of the building wrap must be fitted before a compatible building wrap tape is used to seal the junction of the head flashing and building wrap If head flashings cannot be used an acceptable alternative flashing must be provided NOTE Wall wrap is to have neither tears nor break points Followed by installation of the Exsulite Cavity Spacer where a covit
17. ation 2 1 0 Dulux Acralex Exsulite Trained amp Registered Installer The Building Code Australia BCA requires appropriate design and installation controls to quality any alternate solution and ultimate success requires a total system approach integrating Design Componentry amp nstallation Using a Dulux AcraTex Exsulite Trained amp Registered Installer not only provides peace of mind but also ensures that the final build meets the design specification All Dulux AcraTex Exsulite Trained amp Registered Installer accreditation can be verified by their Exsulite Identification Card and Registration Number Project QA Process is a critical element of the Exsulite total system approach and the Dulux AcraTex Exsulite Trained amp Registered nstaller network ensures total facade system compliance from start to finish 2 1 1 Quality Control Dulux AcraTex Exsulite Trained amp Registered Installers are required to participate in on going refresher training from Dulux AcraTex to maintain their installer accreditation and only a Dulux AcraTex Exsulite Trained amp Registered Installer can provide an Exsulite Certificate of Installation for job sign off 2 1 2 Handling and Storage Exsulite Facade System panels and fixing components should be stored elevated under cover and laid flat Edges and corners are to be protected at all times Dulux AcraTex recommends that the specitied Dulux finishing system be applied to the panels as so
18. covity closer Any remaining condensation or moisture within the cavity can then dry through ventilation provided along the bottom of the cavity and the Exsulite vapour permeable wall wrap A Drainage Cavity System will allow for moisture management as follows A Deflection This first line of defence against moisture water ingress A well designed and constructed Drainage Cavity system will deflect any potential water ingress or condensation away from the vapour permeable wall wrap and frame B Drainage A Drainage Cavity provides a second line of defence against condensation and or moisture water ingress allowing any build up behind the facade system to drain to the bottom of the wall section and out via the weep holes located in the cavity closer at the base of the wall C Drying A Drainage Cavity allows air flow through the bottom of the cavity so any remaining moisture or condensation can be absorbed by the vapour permeable wall wrap and allowed to dry out This drainage cavity is not ventilated to the outside air fo an extent that would compromise the thermal performance of the systems 1 3 1 Design Ultimate Wind Pressures A qualified engineer is to be involved to determine wind pressures based on a buildings geographic location in accordance with the Australian Standard AS4055 for residential housing or wind pressures determined from AS NZS1170 2 Refer to the wind load tables on page 10 for recommended fixing requi
19. d and AcraSkin top coats by Dulux AcraTex has been tested to AS4548 5 1999 Guide to Long Life Coatings for Concrete amp Masonry Testing shows water transmission results of lt g m2 24hr kPa and a vapour transmission rate of 51 9g m 24hr Refer to Dulux AcraTex product data sheets 1 4 7 Penetrations Normal industry standards should be followed for the installation of services into the building In order to avoid disrupting the layout services should be installed through the frame All penetrations through the Exsulite Facade System must allow for differential movement between the installed system and the services All penetrations are a potential source of water ingress and spread of fire and are required to be sealed with a Dulux AcraTex or head contractor approved flexible sealant Back blocking should occur for items such as downpipe brackets outside taps light fittings and other building services to the appropriate locations and apply flashing tape before panel installation 1 4 8 Waste Management Exsulite EPS Panel is a lightweight material that is easily dispersed in windy conditions All waste and cut offs should be stored in plastic bags secured and disposed of in accordance with local regulations Good frame design will minimise the amount of waste generated during the construction process Exsulite Specification amp Installation Manual Version 1 O1 October 2014 1 7 Section 2 Exsulite Facade System Install
20. d by a Dulux AcraTex Exsulite Trained amp Registered Installer to ensure the build meets the design specification System installation and job quality control documentation is project managed by a Dulux AcraTex Exsulite Trained amp Registered Installer to ensure all jobs are installed in accordance with Exsulite Facade System specifications The CodeMark Certificate of Conformity can be provided upon request 1 3 0 Design Considerations Compliance All design and construction must comply with the appropriate requirements of the current Building Code of Australia BCA regulations The BCA is comprised of two volumes The volumes divide the types of building into two groups being Volume 1 Class 2 to Class 9 Buildings and Volume 2 Class 1 amp Class 10 Buildings Housing Provisions All the regulations for construction of buildings are contained in these volumes The Exsulite Facade System is CodeMark certified as a total integrated facade system in compliance with the Building Code of Australia s performance criteria for 1 Structural Performance Wind Resistance 2 Thermal Performance 3 Damp and Weatherproofing CodeMark certification provides building certifiers with the confidence that the system performs against these criteria and together with an Exsulite Certificate of Installation from an Dulux AcraTex Exsulite Trained amp Registered Installer confirms that the build meets the design specification at job completi
21. e 20 2 1 7 Tools Requirements 22 2 1 8 Before Commencing Installation 23 2 1 9 Framing 23 2 1 10 Timber framing must comply with 23 2 1 11 Structural bracing is to be part of the integral wall frame 24 2 1 12 Metal framing must comply with 24 2 1 13 Window Reveals Details 24 2 1 14 Placement of Expansion Joints 24 2 1 15 Fixing Guide 25 2 2 0 Installation Procedure 26 2 2 1 Exsulite Wall Wrap 26 2 2 2 Weatherproof Flashing Tape 26 2 2 3 Exsulite Starter Channel with Weep Holes 26 2 2 4 Cavity Spacer for use in a Cavity System 30 2 2 5 Exsulite EPS Panel amp Composite Panel Fixing 30 2 2 6 Exsulite Fixing Disks amp Screws In accordance with tables 1 2 and 3 re Wind Design 30 2 2 7 Adhesives 30 2 2 8 Control Joints 31 2 2 9 Corner Details gil 2 2 10 Window Details ol 2 2 11 Parapet Detail 31 2 2 12 Balcony amp Terraces 31 This manual is provided as a source of information 2 2 13 Exsulite External Beads amp Angles 32 and is only intended for guidance It cannot fulfil 2 2 14 Joint Sealant 32 the functions of a professional engineering or 2415 Gpaliy fonto 3r x r 2 2 16 Weather amp Temperature Ky design consultancy Professional advice should be sought to determine the suitability of this product for 2 3 0 Dulux AcraTex Exsulite Finishing System Application 33 he es A n l nil building 2 3 1 Standards Of Finish Permissible Variation 34 y 2 3 2 Care Precaution 34 practices should always be ap
22. e additional impact resistance is needed add extra mesh with basecoat NOTE Where texture coating application is to occur within 7 days of Exsulite Matrix Basecoat completion Dulux AcraTex recommends that one coat of Dulux AcraTex Green Render Sealer a high alkali resistant primer is applied in accordance with relevant product data sheets It will help consolidate the surface and enhance subsequent coating application and provide total system durability Exsulite Texture Coating Apply one coat of Exsulite Texture O 8m L in accordance with the relevant product data amp application data sheets PU Sealant Application Install Selleys Flexiseal PU sealant or other approved sealant around all window amp door frames all openings penetrations electrical meter boxes ducting floor amp joist penetrations fixings and any gap that appears where different substrates meet and all other penetrations including plumbing and electrical conduit NOTE Joint Sealant can only be applied once the Exsulite Texture coating has been completed and before the Exsulite weatherproof membrane topcoat Exsulite Membrane Weatherproof protective top coat s Apply Exsulite Membrane or AcraShield Advance or AcraSkin in accordance with the relevant product data and application data sheets NOTE Material consumption will vary pending on surface porosity and application technique allowance is to be made when estimating material quantities Spread
23. ecked and straightened prior to fitting the panels 2 1 10 Timber framing must comply with AS1684 National Timber Framing Code Exsulite Specification amp Installation Manual Version 1 O1 October 2014 23 2 1 11 Structural bracing is to be part of the integral wall frame The Exsulite Facade System does not contribute to the structural integrity of the frame All studs and noggings must be checked with a long straight edge for line and face accuracy to ensure the stud wall has a true and accurate outside face wall frames must be straight plumb and level with a tolerance not more than 3mm to 4mm across a 3 metre span both vertically amp horizontally and be laterally restrained The panel will not straighten any warped frames and any warping may be visible at job completion 2 1 12 Metal framing must comply with AS3623 Domestic Metal Framing A cold ormed steel frame constructed in accordance with NASH Standard for Residential and Low rise Steel Framing Part 1 Design Criteria 2 1 13 Window Reveals Details Exsulite EPS Panel Exsulite Composite Panel Exsulite Cavity Spacer Window Reveal 60mm 15mm 50mm 75mm 25mm 65mm 100mm 25mm 90mm Be sure that the window reveals are sitting 25mm proud of the studs 2 1 14 Placement of Expansion Joints Good building practice provides for expansion joints at 3m max height amp 6m max wide intervals and at all building weak points or where potential c
24. emperature falls below 10 C this is particularly important on exposed southern elevations and may require assistance to dry Refer to individual product data sheets for each component for additional precautions 2 4 0 Care amp Maintenance The exterior coatings should be cleaned on a regular basis This will help maintain your coatings aesthetic appearance and preserve your Dulux Acralex Texture coating system Cleaning on an annual basis will remove light soil as well as grime and airborne pollutants Coastal exposure will have a build up of salt contamination and a six month wash down is recommended All joint sealants should be regularly checked to ensure no cracking is evident to allow water ingress Where cracking is evident sealant will need to be replaced immediately The exterior can be cleaned with a low pressure water blast less than 45Opsi using a fanjet of cold water at a 45 degree angle from the wall not perpendicular The fan of the water blaster should be kept a minimum of 30cm from the surface of the Dulux AcraTex Texture coating in order to avoid damage Localised grime or ingrained dirt should be removed by cleaning with a scrubbing brush along with a solution of detergent and warm water Under no circumstances should you attempt to remove heavy staining using a high pressure water blaster Check for cracked loose or missing sealant as part of your regular maintenance inspections You will find sealant in most areas wh
25. ent to another substrate ie brick amp timber 2 2 14 Joint Sealant Install Selleys Flexiseal PU sealant around all window amp door frames all openings penetrations electrical meter boxes ducting floor amp joist penetrations the gap that appears in between where different substrates meet and all other penetrations including plumbing and electrical conduit NOTE Joint sealant can only be applied once the Exsulite Texture coating has been completed and before the Exsulite Membrane weatherproof topcoat Refer to the Selleys Flexiseal Product Data Sheet for installation guidelines and to the Exsulite Construction Drawings for details 2 2 15 Quality Control During the installation works as per above the Dulux AcraTex Exsulite Trained amp Registered Installer will complete the Exsulite Certificate of Installation Installer Check List to ensure job quality control This then forms part of the project QC documentation confirming that the Dulux AcraTex Exsulite Trained amp Registered Installer has installed in accordance with the Exsulite Facade System Specification amp Installation Manual and is handed over to the project principal 2 2 16 Weather amp Temperature Weather conditions can affect application and drying time Hot or dry conditions and limited working time can accelerate drying times and may require adjustments in the scheduling of work to achieve desired results different to working times in the shade C
26. er Dulux AcraTex ensures the Exsulite Facade System is fit for its specified purpose provided it is installed in strict accordance with the specification amp installation manual and the agreed specification by a Dulux Acralex Exsulite Trained amp Registered Installer 1 1 2 If you are a Dulux AcraTex Exsulite Trained amp Registered Installer Ensure you follow the design amp installation guidelines provided in conjunction with the Exsulite Construction Drawing details Exsulite system components can only be supplied by Dulux AcraTex or other Dulux AcraTex approved suppliers 1 1 3 If you are a Builder To ensure your build meets the design specification make sure all work is completed by a Dulux AcraTex Exsulite Trained amp Registered Installer An Exsulite Certificate of Completion amp Project Warranty will only be issued when the installation is completed by a Dulux AcraTex Exsulite Trained amp Registered Installer 1 1 4 Design amp Installation Any alternative Exsulite Facade System project specific specification outside the standard system must be pre sanctioned by Dulux AcraTex The alternative Exsulite Facade System project specitic specification must be secured prior to job commencement Where an Exsulite Facade System project specitic specification outside the standard approved system is used performance and or appearance of the system may be compromised As a consequence any warranties or guarantees whether expres
27. er amp non reflective Exsulite breathable water barrier wall wrap If condensation occurs moisture can efficiently drain from the cavity through the specially designed starter channels with weep holes that also provide airflow throughout the entire covity Panels are fixed to the vertical cavity spacer EPS H Grade battens and the cavity drains vertically to the bottom starter channel with weep holes The covity spacers battens top hats separate the cladding material from the timber framing It protects the frame from any moisture water ingress and condensation by providing a gap allowing moisture to drain down the outside face of the wall wrap amp cladding and out through the base of the cavity Any remaining moisture within the cavity is able to dry due to the ventilation provided along the bottom of the cavity closer starter channel with weep holes 1 4 3 Exsulite Facade System Composition Exsulite EPS panel is manufactured to AS1366 Part 3 1992 and contains a flame retardant The Exsulite EPS Panel is produced from expanded polystyrene EPS which is a lightweight product displaying self insulative properties that can enhance the energy efficiency of a building The Exsulite Thermal Panel can be used in Class 1 and 10 building applications and can be fixed to steel timber and masonry Toxicity of Exsulite EPS and Composite Panels Exsulite EPS and Composite Panels do not attract ants termites or rodents Howeve
28. eral vertical fixing spacing is 275mm 5 fixings at 275mm spacings and 50mm edge distance top amp bottom for a 1200mm wide panel for most common applications in low wind suburban locations Exsulite Specification amp Installation Manual Version 1 O1 October 2014 Table One For Wind Classification to AS4055 Minimum Panel Thickness and Fixings Wall Areas Over 1200mm Away From Corners Wind Stud Centres 450mm Stud Centres 600mm Classification Min Panel Fixings Fixing Min Panel Fixings Fixing AS4055 Thickness per stud Spacings Thickness per stud Spacings N2 40mm 3 2 5mm 60mm 5 2 5mm N3 60mm 5 275mm 60mm 5 2 5mm NA 60mm 5 275mm 5mm 3 2 5mm N5 5mm 5 2Z5mm 1 00mm 5 220mm Table Two For Wind Classification to AS4055 Minimum Panel Thickness and Fixings Walls Located Within 1200mm from Corners Wind Stud Centres 450mm Stud Centres 600mm Classification Min Panel Fixings Fixing Min Panel Fixings Fixing AS4055 Thickness per stud Spacings Thickness per stud Spacings N2 40mm 2 2 5mm 60mm 5 2 5mm N3 60mm 5 275mm 5mm 220mm N4 60mm 7 180mm 1OO0mm 8 1 50mm NS 75mm 8 150mm 100mm 11 110mm Table Three AS1170 2 Wind Pressure Criteria Design For Buildings That Fall Outside AS4055 Maximum fixing spacings to satisfy design ultimate wind pressures kPa Design Ultimate Stud Centres 450mm Stud Centres 600mm Wi
29. ere different substrates meet ie Above door openings amp windows pipes where walls meet the soffit line and where electrical fittings and handrails have been attached to walls Control joints should also be inspected as part of maintenance inspections All deteriorated or damaged sealant should be removed and replaced as soon as it is apparent We recommend that a paintable polyurethane sealant be used It is important to monitor areas that are heovily exposed to the elements such as parapets and balcony handrail tops Due to the minimal slope on these areas it will tend to hold dirt and grime which can potentially lead to mould over time if not regularly washed These building sections should also be checked for any movement over time due to the extremes of thermal movement so it is critical that they are inspected and maintained Any damage to the texture coating needs to be recoated from edge to edge of the effected wall area to ensure texture and colour consistency If accidental damage occurs please feel free to contact your local Dulux Acralex representative or phone Dulux AcraTex Customer Service on 1300 662 841 and they will provide the support or technical expertise required to help solve the problem Visual cracks may indicate underlying structural problems a professional should always inspect them Temporary repairs can be made to cracks by filling them with polyurethane paintable sealant until the inspection has been completed and perm
30. erformance R value The Exsulite Facade System is CodeMark certified as a total integrated facade system for use as either a cavity or non cavity systems known as A Exsulite Thermal Facade Cavity System B Exsulite Composite Thermal Facade Cavity System C Exsulite Thermal Facade Non Cavity System D Exsulite Composite Thermal Facade Non Cavity System Exsulite Facade System s comprise of Exsulite breathable wall wrap flashing tape to all openings amp penetrations Exsulite EPS Panel or Exsulite Pre Coated Composite Panel Exsulite starter piece cavity closer with weep holes Exsulite fixing components EPS H Grade wall cavity spacers where a cavity system is selected Exsulite Matrix Basecoat with alkali resistant mesh Exsulite Texture and Exsulite Membrane weatherproof protective coating or a Dulux AcraTex Texture and AcraTex Membrane top coat system designed amp supplied by Dulux AcraTex and installed by a Dulux AcraTex Exsulite Trained amp Registered Installer Unless otherwise specitied or approved all Exsulite Facade System components amp coating materials used must be Dulux AcraTex Exsulite products as listed below All system components amp coating products are to be delivered to the job in unbroken containers bearing the brand name and name of the manufacturer and must be subject to the installers inspection amp confirmation of correct materials received in good order Exsulite Specification
31. erior walling system that provides both weatherproofing amp insulation of the building envelope and helps to eliminate thermal bridging that can occur through the wall frame The Exsulite Facade System is designed as a total integrated nontoad bearing lightweight facade system to deliver a weatherproof external building envelope with a self draining cavity for moisture management whilst providing high thermal performance R value The Exsulite Facade System is CodeMark certified as a total integrated facade system for use as either a cavity or non cavity system known as A Exsulite Thermal Facade Cavity System B Exsulite Composite Thermal Facade Cavity System C Exsulite Thermal Facade Non Cavity System D Exsulite Composite Thermal Facade Non Cavity System The Exsulite Facade System comprises of an Exsulite breathable wall wrap flashing tape to all openings amp penetrations Exsulite EPS Panel or Exsulite Pre Coated Composite Panel Exsulite starter piece cavity closer with weep holes Exsulite fixing components EPS H Grade wall cavity spacers where a cavity system is selected Exsulite Matrix Basecoat with alkali resistant mesh Exsulite Texture and Exsulite Membrane weatherproof protective coating or an approved Dulux AcraTex texture and AcraTex membrane topcoat system designed amp supplied by Dulux AcraTex and installed by a Dulux AcraTex Exsulite Trained amp Registered Installer 1 1 1 If you are a Specifi
32. es to where they are to be installed Damp Course Size 300mm x 30m Foam Adhesive 1 x 750ml per 30m approximate only Flashing Tape for openings size 25m roll Selleys Liquid Nails Fast size 300ml allow 1 tube per 12 lineal metres of angles approximate Primer Coat Dulux AcraTex Green Render Sealer optional Selleys Flexi Seal Sealant size 600ml Base Coat Exsulite Matrix Size 20kg Approximately 3m 4mm thick plus wastage 165gsm Exsulite Alkali Resistant Mesh Size 50m x 1m 50m Texture Coat Exsulite Texture Size 15L Approximately 12m Protective Membrane Topcoat Exsulite Membrane Size 15L Approximately 70m NOTE The above calculations are a guide only For project specific requirements please talk to your Dulux AcraTex representative Material estimate guide for typical job lot based as follows Estimate is based on a Exsulite EPS 75mm Panel and 25mm Exsulite Cavity Spacer Metres Squared wall surface Products 60 80 100 om 140 EDS Quantity Required 5mm EPS 2500 x 1200 x 75mm 2O 2 34 40 Am 60 Battens H Grade PK 100 1200 x 40 x 25 2 2 3 4 4 10 Gauge Square Drive Timber 130mm Class 3 Galv PK500 Exsulite Washers AOmm Diameter PK500 2 2 2 5 Breathable Wall Wrap Watergate 2740 x 30m roll 82m Alkali Mesh 1m x 50m 5 x 5mm 50m 2 2 2 3 3 4 Sealey
33. he cladding side of your first wall Using a Dulux AcraTex approved construction PU foam adhesive spray onto all panel edges where the panel is to be joined 2 2 6 Exsulite Fixing Disks amp Screws For 600mm stud centres The required fixings are 5 per stud fixed at 275mm ctrs and 50mm from the top and 50mm from the bottom edge 25 fixings per panel including sheet ends subject to project requirements amp wind design For 450mm stud centres The required fixings are 5 per stud fixed at 275mm ctrs and 50mm from the top and 50mm from the bottom edge 25 fixings per panel including sheet ends subject to project requirements amp wind design NOTE Fixings are to be applied in accordance with Tables 1 2 and 3 on page 10 2 2 7 Adhesives Once the wall panels have been fixed spray adhesive PU foam approved and supplied only by Dulux Acralex into all panel joints Once dry cut off excess with a knife and then sand all joins flush When the total thickness is greater than 50mm apply in multiple layers moisturising each layer 2 2 8 Control Joints Good building practice provides for expansion joints at maximum 3m height amp 6m wide intervals and at all building weak points or where potential cracking may occur e g in line with openings windows doors horizontally between floor levels and at all interfaces of different building construction materials and or as defined by the responsible Building Engineer The placement and c
34. hecklist continued Back blocking required and if so by who Comments By Who Checked expansion joint locations and ensured double studs Vertical expansions joints installed at max 6 0m centres Refer to Exsulite Construction Drawings manual for details Horizontal expansions joints installed at max 3 0m centres Refer to Exsulite Construction Drawings manual for details Checked gable area framing at 600mm max centres Backing plates for fixing of down pipe brackets before panel installation Backing plates to clothes lines pergolas and other external fixtures Checked flashing over roof areas parapets and balconies Checked windows and doors installed with correct reveal size to suit cavity Damp proof course installed to slab rebate e Exsulite breathable absorbent wall wrap installed e If not state alternative breathable wrap installed e Exsulite Cavity spacer installed Cavity spacer thickness mm If not type of cavity spacer installed and by who Type mm
35. ing and hold down requirements should be met by the frame design The allowance of shrinkage in timber framing in BCA 2006 Vol 2 Section 3 3 1 10 by providing gaps between frame and masonry should be adopted as a minimum 1 3 3 Metal framing must comply with AS 3623 Domestic Metal Framing A cold formed steel frame constructed in accordance with NASH Standard for Residential and Lowrise Steel Framing Part 1 Design Criteria NOTE Structural bracing is to be part of the integral wall frame Exsulite Facade System doesn t contribute to the structural integrity of the frame 1 3 4 Slab amp Footings Slab and footings on which the building is situated must be designed and certified by a qualified structural engineer This should comply in accordance with AS2870 Residential Slabs amp Footings and or AS 3600 Concrete Structures as appropriate 1 3 5 Ground Clearance amp Pest Control Install Exsulite Facade System with a minimum 75mm clearance refer to Exsulite construction drawings for details or in accordance with local building codes Adjacent finished grade must slope away from the building in accordance with local building codes typically a minimum slope of 50mm over the first metre Do not install external cladding in areas where it may remain in contact with standing water or debris Do not back fill All BCA and local council requirements must be complied with by the builder of the project to ensure adequate protect
36. inside base of the starter channel prior to installing the Exsulite panel to assist with adhesion of the panel to the starter channel Once tacked into position the screwing of the Exsulite Panels will secure the starter channel into its finishing position at the bottom Refer to the Exsulite Construction Drawings for over roof or slab edge details This may vary subject to individual project requirements When installing the Exsulite starter channel above a deck flat or pitched roof ensure a gap of a minimum 25mm is left between the bottom of the Exsulite starter channel and the finished level Finally ensure that the deck flat or pitched roof has had the correct flashing installed by others is fit for purpose and is sloping away from the wall cladding 27 lt e D 9 SLNIOP T3NVd TVOLLH3A o diIS ONIONOSNISY CNY TWLNOZINOH TIY OL S30V4UNS HSIN SS v 033813 TV3 31NI SNIL33W 4O IYIN 1v Q3QI Osd AINO AINS V SV NMOHS HIIM QV38 N3ONSN HLM SNVHL3UN NOLLOPIHISNOO WvOS 38V SNOISN3MWIQ 31ON Q30803NI3H SH3NHOO TWNYSLX3 TV 318vONVdX3 40 Qv3a 31vnoadv NV 1 H1 9N31 T3NVd 00S2 il T MET SNOILISOd Q 11S YINYO9 NYNLIY LHOISH TANVd ooz SIIYVA 00z SIHVA 00 Exsulite Specification amp Installation Manual Version 1 LHOISH TANVd ooz m gt S1NIOP S381N3O IACIWIXVIN ATIVOLLH3A S38 1N3O ININSZC TANVd TWOILYSA TIY 1Y a3diAodd wwosp LY SONLS s38lNLL 1Y N3HL 3903 TANWd LV SONI
37. ion against pest attack such as termites The requirements vary across different states in Australia Refer to the BCA code and AS 3660 1 2000 1 3 6 Coastal Areas In coastal areas located within 1km of the shoreline or large exposure to salt air a protective weatherproof membrane topcoat must be used in all cases Recommendation is that the facade should be regularly inspected for contamination amp pollutants and washed down accordingly 1 3 7 Colour Selection Avoid the use of dark colours these will raise the surface temperature and can damage the cladding system Use only colours with a LRV greater than 35 or consult Dulux AcraTex on the potential to use InfraCOOL Heat Reflective Coatings that can assist in keeping the surface cooler depending on your colour choice Consult your Dulux AcraTex Representative for project specific requirements Exsulite Specification amp Installation Manual Version 1 O1 October 2014 pur 1 3 8 Control Joints During the life of a building the building and materials that it is constructed from will move This movement is due to many factors such as structure movement thermal expansion amp contraction and differential movement between materials This movement unless relieved or accommodated for will impart stress on the building and construction materials and lead to cracking To accommodate for building movement to relieve stresses and reduce the risk of cracking movement joints must be inst
38. ldton B p imb 7 Region A 39 pred Ceduna astle Head A PERTH CANBERRA Esperance ADELAIDE Region A2 Region B Wagga Wagga 35 Q 59 c DESIT as Wollongong Albany Mount Gambier 70 km S 50 km R Region A5 XS State border Regions are marked with the letters within 70 km j Sale A A1 to A5 B C and D of Melbourne G P O Geelong 40 Coastal Region boundaries are A5 smooth lines set in from a smoothed Launceston coastline by 50 100 150 and 200 km Region A3 Islands within 50 km of the coast HOBART are the same Region as the adjacent coast a Australia 45 NCC Volume Two Class 1 amp 10 Residential Housing Construction AS4055 has a more simplified method of determining wind loads for domestic housing and assists in determining the minimum panel thickness and fixings requirements Design ultimate wind pressures calculated in accordance with AS 4055 Wind loads for housing wind classifications N2 N3 N4 IN5 for wall framing of up to a 600mm maximum stud spacing AS4055 limitations require buildings designed to this standard to be less than 8 5m in height less than 16m in width where the length does not exceed five times the width the roof pitch does not exceed 35 degrees Exsulite Facade System shall be fixed to either steel or timber frames Class 1 and 10 buildings that fall outside this scope require wind pressures to be calculated from AS1 170 2 including regions of high pressures at corners Gen
39. mp installation of any non standard or non approved Dulux AcraTex Exsulite Facade System components will not be the responsibility of Dulux AcraTex and will void any product warranty or claims in relation to product performance 2 1 5 Exsulite Facade System Components Corner angles and expansion beads installed prior to render application Exsulite Breathable Vapor Permeable Wall Wrap Flashing Tape aluminium bituminous self adhesive flashing Cavity Spacer H Grade EPS tape for weatherproofing around zd all window frames including sills Batten where a cavity is to be b doors openings penetrations intersections connections heads and jambs all of which must be flashed prior to panel installation installed Dulux AcraTex approved PU Darij Proof Course expanding foam adhesive Exsulite Matrix levelling coat with L 165gsm alkali resistant mesh Exsulite or Dulux AcraTex Acrylic Texture coating to selected colour with a LRV gt 35 Exsulite Composite Panel Exsulite Fixing Disk amp Class 3 10 Gauge Bugle Head Screws further than 1km of coastal areas Selleys Flexiseal Joint Sealant or as approved by Dulux AcraTex Exsulite Starter Channel with weep Exsulite Membrane or Dulux holes Placed at the base of the A AcraTex AcraShield Advance or cavity these function as a cavity Exsulite AcraSkin weatherproof membrane closer to drain to the exteri
40. n e Check that all eaves and flashings have been completed by the builder to the requirements of the projec specification prior to commencement e Check that the wall wrap installed by the builder is of breathable type and if not advise the builder tha the wrap does not conform and will be required to be replaced with Exsulite wall wrap e Check that correct windows with reveal sizes are fitted in accordance with the project specification Check that the outside of the reveal is flush with the external frame and 1 Omm proud on the inside allowing for the internal plasterboard Make sure that they have been fixed off correctly level and plumb e Check to ensure that the correct damp course has been installed to slab edge and termite treatment has been completed Where no damp course has been installed by others then it must be installed by the Dulux Acralex Exsulite Trained amp Registered Installer prior to the Exsulite wall wrap being installed 2 1 9 Framing The Exsulite Facade System can be fixed to either timber of steel framing All frames should comply with the relevant building code and or Australian standard for the type of construction Studs should be positioned to a maximum of 600mm centres with noggins at maximum of 1350mm centres The frame must be constructed correctly to allow the fitting of the panels so that a true and accurate outside face is achieved If the frame is out of tolerance it should be ch
41. native parapet details panels Where waterproofing is required this should be in accordance with the project specification and project principal Where alternative waterproofing detail is required please refer to the Exsulite Construction Drawings Manual for balcony details 2 2 12 Balcony amp Terraces Where waterproofing is required this should be in accordance with the project specification and project principal Where alternative waterproofing detail is required please refer to the Exsulite Construction Drawings Manual for balcony details Exsulite Specification amp Installation Manual Version 1 O1 October 2014 3 1 2 2 13 Exsulite External Beads amp Angles Once all of the wall area has been installed it is important to go around with a straight edge and make sure that all external corners are plumb and true Rasp off using sandpaper to make sure that all edges are perfectly straight and ready for installation for corner angles amp beading Install 3 5mm Exsulite external bead with Selleys Liquid Nails Fast down the centre of both sides and one run of glue in the junction of the bead Cut a 45 degree angle on both ends of the bead so it finishes flush with the soffit at the top and flush with the starter bead at the bottom Once fitted check it using a straight edge for straightness and wipe off excess glue protruding through slots in the bead NOTE External beads must be installed where the panels are installed adjac
42. nd Pressure Min Panel Min Fixings Fixing Min Panel Min Fixings Fixing AS1170 2 Thickness per stud Spacings Thickness per stud Spacings 1 0 40mm 3 2 5mm 60mm 5 2Z5mm 1 5 40mm 5 2 5mm 60mm 5 275mm 2 0 60mm 5 275mm 60mm 6 220mm 2 5 60mm 6 220mm 5mm 8 150mm 3 0 60mm 7 180mm 5mm 9 1 30mm NC 60mm 8 150mm 100mm 10 1 20mm 4 0 5mm 9 1 30mm 100mm 11 110mm 4 5 Z5mm 10 120mm 5 0 Z5mm 11 110mm 2 5mm 11 110mm Assumption is based on a panel size of 2500mm x 1200mm panel size It is acceptable to use a panel thickness equal to or greater than the minimum requirement to satisfy the wind classification and meet thermal requirements Increased peak pressures occur near the edges of side walls and corners on buildings Using AS4055 the size of the building has been assumed and hence the size of these high pressure zones is specified as within 1 200mm from wall corners NOTE The fixings per stud indicate the number of fixings required at each stud along each sheet 1 3 2 Framing amp Substructure Timber framing must comply with AS 1684 National Timber Framing Code NOTE The timber used in the project must be of sufficient standard in terms of durability to meet the local conditions to which the timber will be exposed such as moisture or insect attack The force applied to the panels by the wind loading is transferred into the stud frame The frame must meet the requirements of the relevant Australian Standard All brac
43. ng alternatively contact Dulux AcraTex on 13 23 77 Safety Information Cutting Outdoors Position the cutting area so that the wind will blow the dust away from workers Use a dust reducing circular saw equipped with vacuum extraction Drilling Machining Sanding Cutting Always wear a P2 mask when performing any activity which produces dust Keep other workers at least 3 metres from the operation Safety Tips Avoid using power saws indoors Only use saws fitted with vacuum extraction Always damp dust with water when sweeping Do not use grinders on this product Follow tool manvfacturers instructions at all times P2 Respirator When performing any activity that produces dust always wear a P2 respirator mask If you have any concerns please contact a qualified industrial hygienist Manual Handling In order to prevent musculoskeletal injuries manual handling of heovy panels should be kept to a minimum and where possible mechanical lifting devices should be employed Where mechanical assistance is not possible more than one person should assist lifting when necessary Weights lifted by individuals should be kept to a minimum Employees should be trained in manual handling techniques A clean work site and good planning will assist in good general safety on site Protective Clothing The wearing of suitable clothing such as long sleeves and trousers and appropriate gloves is recommended
44. on System design should consider factors such as Purpose of structure for Residential or e Bush Fire Attack Levels BAL Mul piste e Acoustics Rw Ctr values location coastal or inland Frame type layout design stud spacing steel Identity BCA performance requirements and any er til additional project specific needs Minimum panel thickness based on wind Wind design actions subject to local jo o wind pressures 555555 5 ef say Colour selection Light Reflective Value moisture ingress or condensation LRV gt 35 Wall wrap vapour permeable for Additional wall insulation to improve condensation control amp weatherproofing energy efficiency e Thermal R Value energy efficiency e Control joint installation Exsulite Specification amp Installation Manual Version 1 O1 October 2014 Benefits of Installing a Drainage Cavity System The Drainage Cavity separates the Exsulite EPS Panel or Exsulite Composite Panel from the frame creating a second layer of defence that allows air flow to dry out any condensation moisture water ingress that may form in the wall or behind the Exsulite EPS Panel or Exsulite Composite Panel as a second line of defence The cavity is created by installing a vertical cavity spacer batten to each wall stud This allows any moisture water ingress to drain down the back of the panel and out through the bottom of the wall via weep holes that are located within the
45. on as possible according to this specification UV rays don t have an adverse effect on the performance of the EPS or Composite Panels during typical construction timeframes however if installation is interrupted for any extended periods of time with the possibility of inclement weather the surface of all panels should be covered in order to provide them with protection If the panels are exposed to inclement weather they will need to dry prior fo any coating being applied Any panels exposed fo an extended period of inclement weather should be replaced prior to installation 2 1 3 Component Checking Damaged EPS or Composite Panels or panels that have been in contact with harsh solvents or acids should not be used EPS or Composite Panels should be stored inside a building where possible Where outside storage cannot be avoided the panels should be stacked elevated from the ground and covered with a polythene sheet or weatherproof tarpaulin It is the responsibility of the Dulux AcraTex Exsulite Trained amp Registered Installer to conduct a stringent quality check of all the Exsulite components prior to commencement of work to ensure the correct product items quantities and colours have been delivered to site in good order and are ready for use Dulux AcraTex will not be responsible for rectifying potential claims where no evidence of the above following installation and job completion is provided 2 1 4 No Component Substitution Design a
46. ool or damp conditions extend working and drying times and may require added measures of protection against wind dust dirt and rain Refer to product data sheets for application guidelines and conditions prior to work commencing 2 3 0 Exsulite Finishing System Application Exsulite Matrix Basecoat with Exsulite Mesh In a clean 15 litre pail add 3 5 4 litres of clean water slowly add Exsulite Matrix Basecoat while stirring until a cream trowelable paste is formed Apply the basecoat layer of Exsulite Matrix Basecoat by stainless steel trowel to fully cover the panel surface with a 2 3 mm min cover Refer to the Exsulite Matrix Basecoat data sheet amp application data sheet for full details Approximate material usage of 1 7kg m mm will vary with application technique Embed Exsulite Reinforcement Mesh into the wet freshly applied Exsulite Matrix Basecoat layer The Exsulite reinforcing mesh 165gsm 5mm x 5mm aperture Once Exsulite mesh is installed and overlapped by min of 100mm on all edges immediately apply additional Exsulite Matrix Basecoat mixture to completely cover and encapsulate the mesh with a minimum of 2mm cover and an overall minimum total thickness of 5mm Additional mesh is to be installed around window and door openings Do not push the mesh to the surface of the cladding Finish the Exsulite Matrix Basecoat layer by lightly scratching the surface to provide a surface key for subsequent levelling coats Wher
47. or at the wa top coat to selected colour with a L bottom of the cavity E LRV gt 35 Exsulite Specification amp Installation Manual Version 1 O1 October 2014 2 1 6 Exsulite Facade System Material Estimate Guide Exsulite EPS Panel size 2500mm x 1 200mm 3m Exsulite Composite Panel 2400mm x 1200mm 2 88m Exsulite Cavity Spacer H Grade EPS Spacer 15mm 20mm 25mm thick and 1 2m long Job size m2 of wall area to be installed Calculate total wall area including openings total m Calculate all openings doors amp windows total m Take total wall area m minus all openings m total m area to be installed Take m of area to be installed plus 10 and Divide by 3 to give you the number of Exsulite EPS panels required OR Divide by 2 88 to give you the number of Exsulite Composite Panels required Exsulite Facade System Screws amp Disks Allow minimum 9 of each per m or 25 of each per Exsulite Panel Exsulite EPS Panel or Composite Panel amp Screws 10G Class 3 Cavity System sizes 105mm screws for 60mm panel with 15mm Cavity Spacer minimum e 130mm screws for 75mm panel with 25mm Cavity Spacer minimum e 50mm screws for 1OOmm panel with 25mm Cavity Spacer minimum NOTE Minimum penetration into timber frame is 30mm Exsulite Breathable Wall Wrap Size 2 7m x 30m 82m Exsulite Starter Channel amp Angles Size 3 metre lengths measure lineal metr
48. orrect installation of control joints is the responsibility of the Building Engineer Builder relative to the construction design Refer to Exsulite Construction Drawings Manual for control joint details 2 2 9 Corner Details Corners are butt joined and glued together with a suitable construction adhesive approved and supplied by Dulux AcraTex being Expanding PU foam adhesive Refer to Exsulite Construction Drawings Manual for corner details 2 2 10 Window Details The panel is fixed to the window head and sill as per section details with the reveals finished Exsulite UV PVC angles should be fixed on all panel edges of door and window reveals and thoroughly glued with construction adhesive and suitably covered with mesh and or reinforced Underneath all window sills leave a 1Omm 1 2mm gap and fit external trims around window Fill the gap with an approved and supplied by Dulux AcraTex construction foam adhesive and when dry cut off flush with the bottom of the window This will allow adequate fall on the window sills at render stage Refer to Exsulite Construction Drawings Manual for window details 2 2 11 Parapet Detail Metal flashing is the preferred recommendation for waterproofing and should be approved by the project consultant refer to Exsulite Construction Drawings Manual for preferred parapet detail Where alternative waterproofing detail is required please refer to the Exsulite Construction Drawings Manual for alter
49. plied and this manual may not contain all the necessary relevant 2 4 0 Care amp Maintenance 35 information Please seek professional advice on all 2 4 1 Health amp Safety 3 aspects of design engineering and installation 2 5 0 Certificate of Installation 37 This manual is to be treated as one document do not separate and distribute individual pages Please visit exsulite com au for the most current Specification and Installation Manual and Construction Drawings Exsulite Membrane topcoat Exsulite Texture coating Acralex Green Render Sealer optional Exsulite Matrix Basecoat 165gsm Alkali Resistant Mesh Exsulite Matrix Basecoat ptem by te Fixings Exsulite pane External angle beads Starter channel with weep holes Cavity Spacers Breathable Wall wrap Timber or Steel frame Exsulite Specification amp Installation Manual Version 1 O1 October 2014 3 Section 1 Exsulite Facade System Specification Light weight wall cladding solutions for specifiers surveyors amp builders This Specification amp Installation Manual is designed to provide fixing guidelines to both timber and steel frame construction as a total integrated light weight self draining cavity walling system This Technical Specification amp Inst
50. r it is not a barrier to them Ants termites and rodents may chew through EPS Foam to reach food or establish a comfortable home Expanded polystyrene products are combustible and should not be exposed to open flame or other ignition sources Insulation material as with other organic material must be considered combustible and constitute a fire hazard if improperly used or installed lgnitability Spread of Flame Heat Evolved Smoke Produced Material Index 0 20 Index 0 10 Index 0 10 Index 0 10 Expanded Polystyrene EPS 12 O 3 5 The above information is as per NPS technical data sheet our supplier Sizes Exsulite EPS Panel 2500mm x 1 200mm Exsulite Composite Panel 2400mm x 1 200mm Standard Thickness 60mm 75mm 100mm other thickness are available upon request Test method Physicol Property M Grade H Grade used to meosure compliance Averoge Densily kg cum 19 24 Compressive strength at kPa 105 135 AS2498 3 10 deformation min Cross breaking strength min kPa 200 260 AS2498 4 Exsulite Specification amp Installation Manual Version 1 O1 October 2014 Exsulite Facade System Performance R Value Performance Smart rate assessment as a total walling system from plasterboard to coating Exsulite Thermal Facade Cavity System Panel Thickness Cavity Spacer Wall Insulation m ok Steen 60mm 15mm R2 0 3 945 2 105 75mm 25mm R2 0 4 337 2 497 10
51. racking may occur e g in line with openings windows doors horizontally between floor levels and at all interfaces of different building construction materials and or as defined by a responsible Building Project Engineer The placement and correct installation of control joints is the responsibility of the Building Engineer Builder to determine if the joints are sufficient to accommodate the movement of the specific project building Typical vertical control joints are 1Omm 1 2mm wide and horizontal joints are 1 5mm 20mm wide and filled with an approved paintable flexible sealant Altematively a U PVC control joint bead is inserted in position prior to render application After the texture coat application the bead is cut through and filled with Selleys Flexiseal Refer to the Selleys specification data sheet Placement of Expansion Control Joints Horizontal Wall Areas Wall length 6 Metres Metres Vertically Construction joints between floor levels and gable ends where the 3 Metres total wall height including gable exceeds maximum distance Scribed control joints Above large window and door openings Note Internal Corner When rendering mesh up to but not across corner then later scribe a control joint into the render cutting nick the mesh intermittently to relieve the tension within the mesh Fill with sealant prior to texture coating 2 1 15 Fixing Guide Exsulite Thermal Facade Cavity S
52. rements Design ultimate wind pressures must account for such factors as site wind speed direction terrain height shielding and topography These project specific considerations should be conducted and approved by a qualified engineer at design stage prior to job commencement to ensure that the final system design is fit for purpose specific to the project and is designed to Australian Standards AS4055 or AS NZS 1170 2 for wind loading requirements The wind load will determine the system specifications Torres Strait Islands B Nhulunbuy C gne B Christmas Island Region B Region C Region B ow D 2 lt Cocos Islands SON AL Region C DARWIN x aw Moreton C Region C Y Q Mareeba Cl D 50 km 7 4 100 k fc j ur Region C 190 kk Kununurra A lt Smoothed Ivanhoe B lt At thartar Q J coastline B Derby C Burketown C T Q ownsville C X J Broome C lt S 25s Pert Hediand Di Normanton C Se 9 Karratha D Collinsville B MA ay E Zl Q Rockhampton C 20 A pton Marble Bar B Q Onslow ID Z MAIS B A Alice Springs Ed 4 i Millstream C N Bundaberg C Region D lt Exmouth D Z Region C IUk SX 25 Carnarvon i A A V Region B H Gascoyne Junction IA Region A4 5 E IB Toowoomba A 61 eCallytharra Springs A ASE Kyogle IB Corindi j Norfolk Island M Mullewa B ag B Bourk A1 NATL Morawa A Region A1 00k A aon g Woomera ar Howe Island Gera
53. required to be fixed to the stud extra supporting back blocking members will be required at panel joints so each panel is individually fixed Panels must not protrude beyond the cavity spacer stud by more than 150mm Back blocking requires full stud width NOTE Adhesive fixed back blocking amp merchant grade timber is not allowed On a single story frame measure 12 10mm up from the rebate at both ends of the wall and flick a chalk line Starting from the corner fit your sheet horizontally and work to your starting line On a double story frame first of all you must complete point 2 2 3 amp 2 2 4 above relevant to the project by measuring 12 10mm up from the rebate and fixing off the bottom row of panels Measure up from the top of the flooring 1 200mm from both ends and chalk a line Fix the first run of panels along this line Work upwards to the soffit then from the bottom of the first run of sheets measure down 1205mm and chalk a line and fix that run of sheets to the line leaving a 5mm gap between the two runs of sheets for expansion Then work down towards the bottom row of sheets that have been fitted to the starter channel Once the first run of panels have been fitted start the second run by measuring down from the soffits eaves 1200mm and flicking another chalk line then fix the top row of panels Once the two runs of sheets have been fixed you will be required to cut a piece to fit in between the panels and complete t
54. s or implied may also be compromised Dulux AcraTex does not approve nor endorse the use of any non standard or non approved Dulux AcraTex Exsulite Facade System components Dulux AcraTex will not be responsible for the performance of a system with nonstandard or non approved components The use of any non standard or non approved components will compromise the system and no product warranty will be issued for the system Exsulite Specification amp Installation Manual Version 1 O1 October 2014 5 a beac ENZ JoL Exsulite Facade System by Dulux AcraTex provides a weatherproof cladding and insulation system for various Residential and Multi Residential applications It can also be installed to masonry amp concrete substrates in accordance with a Dulux AcraTex project specific design fixing specification The Exsulite Facade System is used as a light weight integrated facade system as an alternative to masonry systems in the MultiResidential and Residential Sector Residential External Walls to NCC Volume Two Class 1 and 10 buildings with wind loads to either AS NZS 1170 2 or AS 4055 Wind loads for housing for Wind Classifications N2 N3 N4 N5 within the AS4055 limitations less than 8 5m in height less than 16m in width and where the length does not exceed five times the width and roof pitch does not exceed 35 degrees fixed to either steel or timber frames Integration of System Design Components and Installation is delivere
55. tment boundary or less than 1 8m from a building on the same allotment In these circumstances a FRL is required from the outside of not less than 60 60 60 The Exsulite Facade System has not been tested and is not suitable for use as a FRL rated compliant system for boundary walls and or party walls as a standalone walling system Where a FRL level rating is required for such installation an independent appraisal and approval is needed by a qualified fire engineer Bushfire Attack Levels BAL The Exsulite System has been tested for heat intensity and ember attack of bushfires in relation to AS 3959 2009 Construction of Buildings in Bushfire prone areas Exsulite Facade System has passed AS 1530 8 1 2007 and is approved for use in bushfire prone areas up to BAL 29 1 4 0 System Performance Criteria The Exsulite Facade System is a fully integrated system designed amp supplied by Dulux AcraTex and installed by a Dulux Acralex Exsulite Trained amp Registered Installer in accordance with this Exsulite Facade System Specification and Installation Manual Construction Drawings and in conjunction individual product and application data sheets to all building code and Australian standard requirements The Exsulite Facade System is designed as a total integrated nonload bearing lightweight facade system to deliver a weatherproof external building envelope with a self draining cavity for moisture management whilst providing excellent thermal p
56. x Exsulite Trained amp Registered Installer to ensure that the substrate framework to which the Exsulite Facade System is to be installed to is properly prepared in strict accordance with the relevant Australian Standards Building Code of Australia regulations and project specific requirements Ensure that all preparation work prior to commencement of system installation has been completed by the relevant trades and that the substrate onto which the Exsulite Facade System is to be fixed to is ready for installation work to commence This includes installation of flashings to brickwork window amp door openings and penetrations Ensure wall levels have been checked amp signed off by project site supervisor Where the installer is not satisfied with the substrate standard they are to advise the head contractor prior to commencement of work of these concerns Once the substrate has been rectified to a standard that meets the site agreed sample work only then can the work commence Some checks may include e Check that the frame conforms to the relevant BCA regulations and Australian Standards as well as local standards for structural requirements including wind loadings and bracing Refer to the relevant Exsulite wind design criteria for panel amp fixing based on project specific wind pressures e Check with plumbers and electricians and backblock for any wall mounted services as it is imperative that this is done prior to panel installatio
57. y system is being used fixed to each stud 2 2 2 Weatherproof Flashing Tape Install Dulux AcraTex supplied Flashing Tape aluminium bituminous selFadhesive flashing tape for weatherproofing around all windows frames including sills doors openings penetrations intersections connections heads amp jambs and must be flashed prior to panel installation It must cover both wall wrap and substrate to ensure a closed weatherproof seal is achieved 2 2 3 Exsulite Starter Channel with Weep Holes The starter channel must be installed 10 1 5mm above flashings and 25mm above the base of the wall frame and needs to be set to a 1 in 12 fall to allow drainage of any moisture that may occur from the top Contact with the ground is not permitted and a 75mm gap must be maintained Exsulite Starter Channel N Aluminium Stainless Steel Clouts 30mm Timber Frame PVC Galvanised Clouts 30mm Aluminium Stainless Steel Screw With Twin Seal 25mm Steel Frame PVC Self Drilling 12 Gauge Metal Screw 20mm e 27mm install with a Aluminium Collated Drive Pin Power Walli CS iod Concrete dilland PVC Round Head Nylon Nail Drive Anchor EOS MEN knock in NOTE No back filling Therefore there will be no capillary provided that the starter channel and coating are correctly installed The starter channel must be butt joined and sealed on the junction with an approved PU sealant Apply Selleys Liquid Nails Fast Grab to the
58. ystem Residential Housing Vol 2 Class 1 amp 10 Frame Panel Cavity Starter Channel Minimum e G Type Thickness Spacer weepholes Screw Length oa sss ue 60mm 15mm 75mm 105mm 3 10 Bugle Needle Point Timber 75mm 25mm 100mm 130mm 3 10 Bugle Needle Point 100mm 25mm 125mm 165mm 3 10 Bugle Needle Point bom dee mi l05mm 3 us E rat use up lo O 55mm steel Metal 75mm 25mm 100mm 130mm 3 jo eae noinen use up to O 55mm steel 100mm 25mm 125mm ionn a seeks Polntier use up to O 55mm steel Frame Panel Starter Channel Minimum Screw G T Type Thickness weepholes Screw Length Type Class EE Ms 60mm 60mm 105mm B 10 Bugle Needle Point Timber 75mm 75mm 105mm 10 Bugle Needle Point 100mm 100mm 130mm 3 10 Bugle Needle Point ORI 60mm 105mm 3 0 Bugle Needle Point for use up to O 55mm steel Metal 75mm 75mm 105mm 3 ic SERM use up to O 55mm steel 100mm 100mm 130mm 3 10 Bugle Needle Point for use up fo O 55mm steel NOTE Needle point screws used for timber frame fixing applications can be used in light gauge steel frame fixing depending on the length of the screw A minimum of 3 full threads need to be screwed through the steel The needle points can pierce through 0 55mm steel Where heavier gauge steel is used and exceeds 0 55mm a self drilling metal screw is required to be used Within 1km of a coastal environment Cl
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