Installation Manual
Contents
1. Quality Endorsed Company E N E 77 7 2 Environmental Management AS NZS ISO 14001 2004 Y CODEMARK CMA CM40006 For further information go to www exsulite com au Customer Service 300 662 841 Dulux AcraTex 1 Jeanes Street Beverley SA 5009 Dulux Acralex is a division of DuluxGroup Australia Pty Ltd ABN 67 000 049 427 Dulux and AcraTex are registered trade marks and Exsulite is a trade mark of DuluxGroup Australia Pty Ltd 5707 04 132. each individual panel must be nogged out and fixed on both sides the sheets must not be fixed with washers through the join Applying Foam Adhesive External Door Bead External Window Bead Expansion Bead over window Expansion Joint into Starter Channel Garage Head Eco c NNT 6 i FIXING COMPONENT DETAILS TABLE THREE NA Within 1200mm from corners of buildings use 6 screws stud 220mm cts Within 1200mm from corners of buildings use 8 screws stud 157mm cts Exsulite Installation Manual Page 9 Exsulite Thermal Facade System Installation Guide Step Thirteen Once the wall has been fixed off spray adhesive foam onto all joints Once dry cut off excess with a knife and then sand all joins flush Step Fourteen Expansion joints should be placed at no more than 6 metres on horizontal walls and no more than 3 metres on the vertical walls reter to Table Four It is always recommended that sliding doors have expansion joints above them PLACEMENT OF EXPANSION JOINTS TABLE FOUR Placement of Expansion Control Joints Horizontal wall areas wall length Vertically Construction joints between tloor levels and gable ends where the total wall height including gable 2 Metres exceeds maximum distance 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
3. area to ensure texture amp colour consistency If accidental damage do occur please feel free to contact your local Dulux representative or phone Dulux Customer Service on 1300662841 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 permanent repairs under taken 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 to the texture coating is recommended over a 7 10 year period to rejuvenate your homes appearance This can be done by using 969 Acralex Acraskin protective membranes coating to a selected Dulux colour which will protect your house from air pollutants water ingress and dirt accumulation providing a low maintenance surface on completion Advice and product availability can be obtained from nearest Dulux Trade Centre or phone Dulux customer service on 1300662841 or visit our website wwNw dulux com au Exsulite Installation Manual Page 16 Kera Tr
4. control joint into the render cutting nick the mesh intermittently to relieve the tension within the mesh Fill with sealant prior to texture coating Curved Exsulite Walls Step Fifteen Curved walls with a radius greater than 2 4 metres can be fitted with 40mm and 60mm Exsulite Thermal Panel refer to Table Five Where a tighter radius is required use multiple layers by laminating 20mm thick Exsulite Thermal Panel by using an approved construction foam adhesive and fix by using off set joints CURVED WALL SPECIFICATIONS TABLE FIVE estan Rab E E Lj F rl E amp Tei a Exsulite Installation Manual Page 10 Exsulite Thermal Facade System Installation Guide Step Sixteen Once all of the wall area has been clad 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 pertectly straight ready for beading Step Seventeen Underneath all window sills leave a 12mm gap and tit external trims around window Fill the gap with an approved 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 Starter Channel The Exsulite Starter Channel should be fitted neatly along the bottom of the sheet and cut neatly on a 45 degree angle on all external corners This is glued on u
5. e Certificate of Installation checklist and QA sign off Mu ona Certificate of Installation n is for use by a Exsulite Tr The Exsulite Certificate of Installatioi y rained amp Registered Installer as a Quality Control Document to cordi with the Exsulite Installation procedures as set out in lo Comments By Who lo Comments By Who Exsulite Installation Manual Page 5 Exsulite Thermal Facade System Specifications Exsulite System Components e Exsulite EPS Thermal Panel refer to Fig A TM e Exsulite Breathable wall wrap refer to Fig B e Exsulite Cavity Spacer refer to Fig B e Exsulite Starter Channel and Corner Angles These are UV Stabilized and protect all exposed EPS surfaces They consist of Exsulite Starter Channel refer to Fig C External Angles refer to Fig D Expansion Joint Trim refer to Fig E e Expanding Foam Adhesive refer to Fig F e Selleys Liquid Nails Fast e Flexible approved paintable PU sealant e Exsulite Washers 40mm diameter refer to Fig G e Exsulite Class 3 screws 10 gauge screws should always be long enough to fix into the stud by a minimum of 25mm refer to Table Three refer to Fig H e 40mm x 2 5mm hot dipped galvanized steel flat head na
6. into position the screwing of the Exsulite Thermal Panels will secure the Starter Channel into its tinishing position at the bottom The Channel must be butt joined and sealed on the junction with a marine grade sealant or similar Step Six When installing above a deck flat or pitched roof leave a gap between the bottom of the Exsulite Starter Channel and the finished level Refer to the Exsulite construction drawings for details Be sure that the window reveals are sitting 25mm proud of the studs glue or nail the 40mm x 25mm Spacers onto all studs and around all windows and doors and ensure that they are finishing hard down on the edge of the Exsulite Starter Channel Finally ensure that the deck is sloping away from the wall cladding L Cavity System installation Exsulite Installation Manual Page 8 Exsulite Thermal Facade System Installation Guide Step Seven Once tully battened check with a straight edge to ensure the wall is level to within a 3mm tolerance You are now ready to commence cladding Continue to step eight Step Eight Measure and cut Exsulite Thermal Panels using a masonry diamond blade in a standard power saw or a hot knife Step Nine On a single story frame measure 1210mm 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 complete Step Five by m
7. per litre 16 hours Apply with Hawk amp Trowel evenly over surface to the thickness of the largest particles Follow up with a light floating process to level out the product using red plastic trowel tloat High Performance Membrane FINISHING COATS NB Acraskin colour must have a LRV greater than 35 Dulux AcraTex Acrashield L Shade 194 85675 Pastel aie tion Apply Acrashield with a medium nap roller over the surface ensuring a wet DA 1600 6 m per Litre frost and rain edge is maintained over the application area Whilst one coat over EPS per Coat in first Cladding may provide adequate protection and resistance to the elements 16 hours Dulux recommends 2 coats applications for even coverage to minimising cutting in and lap mark effects Where 2 coats are applied dilute the first coat with 10 water Where an alternative Exsulite system specification is required this must be pre sanctioned by the authorised Exsulite Technical Engineers not your Dulux Representative The amended alternative project specitic Exsulite System Specification must be secured prior to job commencement Installations of any non standard or non approved Dulux Exsulite system will be void of system warranty or claims Exsulite Installation Manual Page 14 Important Notes Practical spreading rates will vary from quoted theoretical figures depending on substrate porosity surface roughness overspray losses appl
8. system for new residential and low rise commercial construction It can also be used as a facade remedial system for rectification and rejuvenation of aged facades when used as a direct fix system Exsulite Thermal Facade System is CodeMark certified and compliance to the Building Code of Australia BCA full range of performance criteria in including structural stability wind resistance durability thermal resistance weatherproofing and dampness and can be used in Class 1 and 10 building applications fixed to steel timber and masonry surfaces System installation and job quality control documentation is only done by a Dulux trained Exsulite amp registered installers ensuring all jobs are installed in accordance with BCA amp Exsulite Thermal Facade system specifications Exsulite 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 Thermal Facade System has passed AS 1530 8 1 and is approved BAL 29 for use in bushfire prone areas Where a Higher rating than BAL 29 is required contact a Dulux Acralex representative Users of this specification will satisty themselves of the suitability of this specification advice relevant to their specific project requirements In all cases Building System Design must conform to relevant Local Building Codes or regulations Variation and Modifications to the Exsulite Thermal
9. Class 10 residential building Exsulite CodeMark certification provides CODEMARK building certifiers confidence in total design NMA cm4o006 and componentry and together with an Exsulite Certiticate of Installation trom an Exsulite Trained Installer contirms as built meets design Y 1 CodeMark Certificate of Conformity confirms Exsulite as a Fully Integrated Facade System complies with the relevant BCA clauses relating to e Structural integrity e Energy Efficiency e Weatherproofing e Approved Componentry No substitution Integration of System Design Components and Installation is delivered through Exsulite Trained Installers to ensure as built meets design specification System installation and job quality control documentation is project managed by a Dulux trained Exsulite installer ensuring all jobs are installed in accordance with Exsulite Thermal Facade system specifications The CodeMark Certiticate of Contormity can be obtained on request Bushfire Attack Levels BAL Exsulite has been tested for heat intensity and ember attack e Weatherproof membrane topcoat of bushfires in relation to AS 3959 2009 Construction of Buildings in Bushtire prone areas Exsulite Thermal Facade e Total design amp supply by Dulux AcraTex e Cavity System e Moisture management System has passed AS 1530 8 1 and is approved for use e Suitable for bushtire prone areas in bushfire
10. Facade System Dulux reserves the right to alter the base system as defines herein trom time to time in an effort to improve the overall quality and performance of the cladding system Where such variations occur Dulux will keep the Installer advised in writing before these variations come into effect Additionally the yearly training will identity and communicate all systems variations modifications which the Installer will need to adopt Exsulite Thermal Facade Panel M grade is made to Australian Standard AS1366 3 1992 Exsulite Thermal Panel is treated to defend against vermin and insects and has a flame retardant additive to inhibit accidental ignition from a small flame source Exsulite Thermal Panel is produced from expanded polystyrene EPS a lightweight cladding system that displays seltinsulative properties and once installed amp coated with Acralex finishing coatings creates a weatherproof barrier that will enhance the energy efficiency of the building Substrate Preparation Check that the frame is plum amp level with a tolerance 5mm across 3 meter span both vertically amp horizontally Exsulite Thermal Panel will be installed and fixed in accordance with Exsulite Installation manual specification amp installation procedures Only Exsulite components amp Acralex finishing coatings supplied by Dulux can be used and cannot be substituted by third party alternatives Once the Exsul
11. Installation Manual Current May 2013 Exsulite Thermal Facade system by Dulux Contents WY RO I I cares ET CE 3 Exsulite Material Estimate IS essersi herren etm cates annnee uos dias I UR Dm AME En adsmamessteusabutedanenderdnen acabiaaeeasGuasreceanicont 4 Plone end SORGE tga crete eons vet OPPRESSUM size Deren Sauna bo chores maw i E DN diaeteM aq dodi 4 Exsulite Thermal aleleolo e EU TNT OTT 5 EDELE lo LN TINI 6 aS fell fo irelg evite EAE E A EA A A A E 8 e de T a T a a ENA ESE E 8 Sed e A a E E E E E E A ES 9 Scc aM HT m 10 sco HH 1 SSN rz ral B To CAT BENNETT RC ees 1 due Miele se Ane NIIT ET D 1 Exparsiondomb BAIS cerises enetice A TE E E A EE NA dat NIE RURSUM NU MUN 11 Campling N erar E a ex AEE aM AE A AN ae ae ote M EU eee UE 11 Acra le Acrylic Finishing Oy SIEM cane riasbasatissaiatisa E EA AN ai shen A A E TECE ENa 11 Exsulite Thermal Facade System Installation Guide ssssssseeseeeeeeennennne nennen nnne 12 SUM nisle eee io EE EET TT TR TT TT 13 Texture Coating System JS Spedito lene a aS E d eden a med aloe ne eee DN DIR DOT 14 PONO eaa E EL E E OD C LOT DN 15 Dulux Acrylic Texture Coating Care amp Maintenance ccccccccccssccssecesseccseeesse
12. anel with 25mm Covity Spacer e 165mm screws for 100mm panel with 25mm Cavity Spacer 5 Exsulite Breathable Wall Wrap Size 2 7m x 30m 82m Exsulite Starter Channel with weep holes amp angles Size 3 metre lengths 2 measure lineal meters to where they to be installed 5 for wastage Damp Course Size 500mm x 30m Foam Adhesive 1 x 750ml per 30m Flashing Tape for openings size 25m roll 10 Selleys Liquid Nails Fast size 300ml allow 1 tube per 12 lineal meters of angles 1 Selleys Flexiseal Sealant size 600ml l Exsulite Alkali Resistant l160gm 165gm Mesh Size 50m x 1 m 50m 14 Primer Coat Acralex Green Render Sealer Size 15lt 120m 2 15 Texture Coat Acralex Coventry Course Size 15lt 12m 16 Protective Membrane Topcoat Acralex Acraskin Size 15lt 60m efaltelsis sfsjole siotet fef oe Note The above calculations can be used as a guide only and for project specific requirements please talk with your Dulux representative Handling and Storage Exsulite Thermal Panels and Fixing Components should be stored elevated under cover and laid flat Edges and corners are to be protected at all times Prolonged exposure to direct sunlight and elements should be avoided Exsulite Installation Manual Page 4 Exsulite Thermal Facade System Wall cladding solutions for certifiers amp builders Acralex is a pioneer in the use of EIFS systems designing and installing
13. cessecesecesseccssecessecessecessecessecseeceseecssseceseeeseeesaeens 16 Exsulite Installation Manual Page 2 Introduction Exsulite Thermal Facade System installation manual and construction drawings are designed for fixing to both timber and steel frame construction as a total integrated light weight cavity walling system Designed to deliver weatherproof external building envelope cavity moisture management and providing high thermal R values The Exsulite Thermal Fa ade System is CodeMark certified comprising of Exsulite M Grade termite treated thermal EPS panels breathable wall wrap cavity spacers fixing components Exsulite PAOO Basecoat with alkali resistance mesh and Acralex finishing weatherproof coating system which is designed amp supplied by Dulux Acralex and installed by Dulux Exsulite Trained amp Registered Installer Where an alternative Exsulite system specification is required this must be pre sanctioned by the authorised Exsulite Technical Engineers The amended alternative project specific Exsulite System Specification must be secured prior to job commencement Installations of any non standard or non approved Dulux Exsulite system will be void of system warranty or claims CodeMark Certified Fully integrated system by Dulux Acralex Exsulite is CodeMark certitied as a tully integrated Building System in compliance with the Building Code ot Australia Volume 2 Class 1 amp
14. cular The fan of the water blaster should be kept a minimum of 30cm from the surface of the Acralex 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 where different substrates meet and 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 if the maintenance inspections All deteriorated or damaged sealant should be removed and replaced as soon as it appears We recommend that a paintable polyurethane sealant be used It is important to monitor areas that are heavily exposed to the elements such as parapets and balcony handrail tops Due to the minimal slope on these areas will tend to hold dirt amp 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 it is critical that they are inspected and maintained 6 Any damage to the texture coating needs to be recoated from edge to edge of the effected wall
15. d system is to be installed is properly prepared in strict accordance with the relevant Australian Standards amp Building Codes ot Australia requirements Ensure that all preparation works prior fo commencement of system installation have been completed by the relevant trades and that the substrate frame is in readiness for installation works to commence including installation of tlashings to brickwork windows and door openings Step Two Install the Exsulite Breathable Wall Wrap to properly prepared timber or steel trame They must tit the appropriate head flashings over the top of the building wrap then a compatible building wrap tape should be used fo run over the junction of the head flashing and building wrap If head tlashings cannot be used an acceptable alternative tlashing must be provided Followed by installation of the Exsulite Cavity Spacer fixed to each stud Bulkheads Step Three en Flexible sill and jamb flashing tapes complying with Australian Standards must be used around all penetrations Step Four The Exsulite channel is to be installed as specified in the Exsulite Construction Drawings relevant to the project A requirements Refer to the Exsulite construction drawings for details iL Step Five Chalk a line around the base of the building at the lowest point the cladding is to be fixed Fit the Exsulite Starter Channel using 30mm x 2 0mm stainless steel clouts i Once tacked
16. easuring 1210mm up from the rebate and fixing off the bottom row of panels Then measure up from the top of the flooring 1200mm from both ends and chalk a line then fix the first run of panels along this line work upwards to the sottits 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 in 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 Step Ten Once the first run of panels have been fitted start the second run by measuring down from the soffits 1 200mm and flicking another chalk line then fix the top row of panels Step Eleven 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 the cladding side of your first wall Using an approved construction foam adhesive spray onto all surfaces where the panel is to be joined Step Twelve Fixing Exsulite washers and screws refer to Table Three i When the panel is laid horizontally fix screw and washer 50mm from the top and 50mm from the bottom edge of the sheet to centre of screw at maximum of 450mm stud spacing ii One row of fixings through the centre of the sheet at a maximum of 450mm stud spacing iii Two rows of fixings approximately 275mm apart top and bottom of centre line of fixings iv When fixing the ends
17. exture coats Note The mesh is not to be pushed through the wet render onto the face of the Exsulite Panel nor is to be applied direct to the Exsulite Panel 2mm 16 hours Assuming no loss Note A minimum 3 5mm cover of PAOO Renderwall to the Exsulite Panel once dried Where additional impact resistance amp optional levelling coat is required Data Sheet Levelling Layer Where additional impact resistance is required apply and embed an additional Exsulite reinforcement mesh layer coat of PAOO Renderwall as specified or directed Add Renderwall P400 to fresh water to form trowelable paste Apply by hawk DAO443 ND 2 m M P400 16 hours and trowel or render pump over the Base Coat application Screed and float level finish by polystyrene or wood float to a suitable level finish for subsequent Texture Coating TEXTURE COATING SYSTEM APPLICATION Application rate Optional primer coat Dulux Acralex Green Render Sealer L Shade 194 20802 The use of Green Render Sealer consolidates and conditions the surface and enhances subsequent coating application and total system durability Apply by DA 1582 8 0 sq m per litre 4 hours conventional roller method evenly over the surface Note Is to be uses when the texture finishing coati is to be applied over the P400 Render less than 5 days Texture coat NB Texture colour must have a LRV greater than 35 Dulux AcraTex Coventry C L Shade 194 85753 Mo Rd erence once DA1065 O 8 sq m
18. ge 1 1 i pi UA EN A Window Sill Parapet wall Exsulite Installation Manual Page 11 Exsulite Thermal Facade System Installation Guide 4 LU S RR ita ee OR Re i RR Routine med Pis ramis rtg RT Varta Num on Nen p ae by NONO pE rp nm inn fi i ng Pn i fn ii gre hs ee a WT TM Application of Dulux Exsulite P400 Basecoat Applecien a pur Sauls PAGO Erst with Exsulite alkali resistance mesh Dulux Application of Dulux Exsulite P400 Basecoat i Finishing Dulux Exsulite P400 Basecoat Ee Apply Dulux AcraTex Acrylic Texture Apply Dulux AcraTex Acrylic Membrane Top Coat Exsulite Installation Manual Page 12 Exsulite System Specification Introduction Exsulite Thermal Facade System by Dulux Acralex is total integrated facade light weight walling system Designed to deliver watertight external building envelope cavity moisture management and providing high thermal R values The system comprises expanded polystyrene thermal panels wall wrap cavity spacers fixing components Exsulite P400 Basecoat with alkali resistance mesh and Acralex finishing weatherproof coating system which is all specified amp supplied by Dulux System installation is by a Dulux trained Installer in accordance with Exsulite Thermal Facade System guidelines amp procedures manual Exsulite Thermal Facade System by Dulux Acralex is a cavity drainage
19. ication methods and environmental conditions e g wind Protect each application trom rain and trost tor 24 hours when apply at the recommended spread rate Dry times apply to a single coat at recommended spread rate and at 25 C and 50 Relative Humidity Allow longer times under cool moist or still conditions and or when applied at high film builds Do not apply paint if Relative Humidity is above 85 or temperature is within 3 C of Dew Point Do not apply if the surface temperature is greater than 40 C or below 10 C or likely to fall below 10 C during the application or drying period When using Bright Reds Oranges Blues and Yellows or where very light colours are applied over highly contrasting colours an extra coat maybe required At Commencement of coating system application to the substrate it shall be deemed that the Applicator has certified that the surface which it is to be applied to is fit receive the specified coating s system Consult Dulux on the potential to use IntraCOOL Heat Reflective Coatings that will keep the surface cooler Glancing Light Joints and panel deformation may be clearly evident under glancing light casting visible shadows of the minute and uneven projections of the joints Glancing light is light that is nearly parallel to the surface of the wall and casts visible shadows and uneven projections of the joints Just like rendered masonry Jointed system any uneven projections wil
20. ils to timber frame or construction adhesive for temporary fixing to building wrap fixed over timber or steel frame e Flashing tape for use around window and door joinery to be installed by the installer during installation refer to Fig e Basecoats Exsulite PAOO Renderwall e Alkali Resistant Mesh Exsulite Mesh 165gsm m 5mmx5mm refer to Fig J e Texture Coats Dulux Acralex acrylic texture coating system s e Finishing coats Dulux Acralex flexible weatherproofing texture systems with protective membrane topcoat E 1 amp I I a r Ane EE 1 7 Gs i n i x pig A j d F Y 1 L l i ja 2 i i q j F 5 D rum er n T s Lond Tas T E i j P l i i E 4 L WINDOW REVEAL DETAILS TABLE ONE Exsulite Exsulite Window Reveal EPS Panel mm Cavity Spacer mm mm f Di fee Fig B Exsulite Breathable wall wrap amp Exsulite Cavity Spacer Fig H Exsulite Class 3 screws Fig I Flashing Tape Exsulite Installation Manual Page 6 Exsulite Thermal Facade System Specifications L E E Cavity System set out showing EPS Exsulite Cavity Spacer and Exsulite Breathable Wrap i 0 M Before Commencement e Read the Exsulite Installation Manual amp Exsulite Construction Drawings to familiarize yourself with the relevant details relevant to the project and sy
21. ite Thermal Facade Panel has been in installed in accordance with the Installation manual specification amp installation procedures and Exsulite job Certificate of Installation has been completed and signed off by an Exsulite Trained Installer only then can the Acralex specified finishing coating system application can commence Note Exsulite Raw sheet surface will NOT be left exposed to degrade causing the surface to discolour harden or change surface properties Remove any surface contaminants such as oil grease or dirt Wash and or Broom Scrape down to remove all contaminants and triable surface materials Expansion Joints Good building practice provides for expansion joints at max 3m height amp 6m wide intervals and at all building weak points or where potential cracking may occur e g in line with openings window doors horizontally between tloor levels and at all interfaces of different building construction materials and or as defined by the responsible Building Engineer The placement and correct installation of control joints is the responsibility of the Building Engineer Builder relative to the construction design Caution on Dark Colours Avoid the finishing of EIFS Claddings with dark colours these will raise the surface temperature of the EPS and damage the cladding system Use colours with a LRV greater than 35 or consult Dulux on the potential to use IntraCOOL Heat Reflective Coatings tha
22. l be highlighted and as such are outside the control scope of this specification When using this specification the Installer shall maintain records in accordance with the Exsulite Installer Agreement amp Certificate Of Installation and any others records as required by the Project Manager These records shall be made available for inspection at any time by the Project Manager or Dulux Acralex authorised representative and shall be submitted to Dulux AcraTex upon completion of work Where an alternative or project specific Exsulite system specification is required this must be pre sanctioned by the authorised Exsulite Technical Engineers not your Dulux Representative The amended alternative project specific Exsulite System Specification must be secured prior to job commencement Installations of any non standard or approved Dulux Exsulite system will be void of system warranty or claims Exsulite Installation Manual Page 15 Dulux Acrylic Texture Coating Care amp Maintenance The exterior texture coatings on your home should be cleaned on a regular basis This will help maintain your homes aesthetic appearance and preserve your Acralex Texture coating system Cleaning once every year will remove light soil as well as grime and airborne pollutants The exterior can be cleaned with a low pressure water blast less than 450psi using a fanjet of cold water at a 45 degree angle from the wall not perpendi
23. prone areas For BAL system specifications amp e CodeMark compliance installation guidelines please call Dulux Acralex or your representative for further information EWFA e High R Value Certiticate ot Assessment Number SFC 27615 e Installed by a Dulux Exsulite trained Installer Exsulite Installation Manual Page 3 Thermal Facade System Material Estimate Guide 1 1 Exsulite EPS Thermal Panel size 2500mm x 1 200mm 3m 1 2 Exsulite EPS Composite Panel size 2400mm x 1200mm 2 88m 1 2 Exsulite Cavity Spacer H Grade EPS Spacer Dimensions 15mm 20mm 25mm thick and 1 2m long Job size m of wall area to be installed 2 1 Calculate total wall area including openings total m 2 2 Calculate all openings doors amp windows total m 2 3 Take total wall area m minus all openings m total m area to be installed 2 4 Take m of area to be installed plus 10 divide by 3m to give you the number of Exsulite EPS Thermal Panel needed for the job 2 4 Take m of area to be installed plus 10 divide by 2 88m to give you the number of Exsulite EPS Composite Panel needed for the job Exsulite Fixing Screws amp Fixing Disks Allow a minimum 25 of each per Exsulite EPS Thermal amp Composite Panel when for fixing at 600mm centres Exsulite System Screws Class 3 as follows e O5mm screws for Omm panel with 1 5mm Cavity Spacer e 30mm screws for 5mm p
24. sing an approved EPS construction adhesive Make sure that the bottom bead is gun barrel straight as this is the finished line External Beads amp Angles Install 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 Expansion Joint Beads On the horizontal expansion joint line mark on the foam the top of the bead at both ends and chalk a line through so the bead can be glued on straight Cut a 45 degree angle to the end of the bead where it is going to join the external beads or Starter Channel Glue the bead with an approved EPS construction adhesive using a generous amount and wipe away any excess protruding through the slots in the bead refer to Table Four Completing Work The Exsulite Installation Guide has been developed to ensure you have all the required information to design plan and install the Exsulite Thermal Facade System prior to the application of Acralex high build acrylic texture coatings AcraTex Acrylic Finishing System Once you have completed the install checklist application of the nominated Acralex Coating System can commence refer to Acralex specifications on pa
25. stem components required to install the Exsulite system e Check that the frame is plum amp level with a tolerance 5mm across 3 meter span both vertically amp horizontally e Check that the frame conforms to the relevant BCA and Australian Standards as well as local standards for structural requirements including wind loadings and bracing refer to Table Two e Check with plumbers and electricians and back block for any wall mounted accessories as it is imperative that this is done prior to cladding e Check that all flashings have been completed by the builder or roof plumber to the requirements of the BCA prior to commencement e Check that correct window reveal sizes are fitted and the outside of the reveal is flush with the external frame and Omm proud on the inside allowing for the internal plasterboard Make sure that they have been fixed off correctly level and plumb BUILDING WIND ZONES NON CYCLONIC REGIONS TABLE TWO Wind Minimum Exsulite Thermal Ultimate Wind Classification Panel Thickness mm Speed mls Type B N2 N3 Type C N4 Type D N5 d 1 p i L 4 7 z a I M 4 ji yk gt A Aem Penetration flashings below expansion joint cas Exsulite Installation Manual Page 7 Exsulite Thermal Facade System Installation Guide Step One Cavity System It is the responsibility of the contractor to ensure that the substrate tramework to which the Exsulite specifie
26. systems specifically for Insulation benefits as originally used in Europe In recent years the use of Lightweight Cladding Systems as Alternate Solutions in the BCA has grown but proper system design and installation has not followed The BCA requires appropriate design and installation controls to quality any Alternate Solution and ultimate success requires a total systems approach integrating Design Componentry amp Installation The Exsulite Thermal Facade system protects surveyors builders and their Clients trom the risks of mixed componentry and uncontrolled installation Exsulite by Dulux Acralex offers a Single Supply Source for the Total Facade System Cladding to Weatherprooting Coating Exsulite EPS Panel Exsulite Thermal M Grade Panels can be cut to any desired thickness but dependant on application and required R value we recommend from a range of standard panels 60mm 75mm 100mm The sheet dimensions are 2500mm x 1200mm and are manufactured to meet the requirements of AS 1366 3 1992 How does a Cavity System work The Exsulite Thermal Facade Cavity System is recommended in areas with significant variation between internal and external temperatures If condensation occurs moisture can efficiently drain from the cavity through the specially designed starter beads and provide airtlow throughout the entire cavity The cavity separates the cladding material trom the timber framing It protects the
27. t will keep the surface cooler Caulking amp Sealant Recommendation is to have all the joints are sealed filled after the application of the texture coating to avoid potential cracking amp delamination of the texture coating from the sealant Dulux recommends the use if Selleys Flexiseal or 8 in Sealant or as approved Exsulite Installation Manual Page 13 AcraTex Coating System Application TABLE SIX Basecoat amp Reinforcement Mesh Surface Levelling Renderwall PAOO 1 7kg m mm Assuming no loss PAOO renderwall base coat with Exsulite reinforcement mesh In a clean 15 litre pail add 3 5 4 0 litres of clean water slowly add Renderwall PAOO while stirring till a cream trowelable paste is formed Apply the basecoat layer of Renderwall PAOO by stainless steel trowel to fully cover the EPS surface with a 2 3 mm min cover Whilst wet embed the DAOA43 Y 2 3mm Exsulite reinforcing mesh into the PAOO Renderwall and overlapped all edges Alkali resistant wen AI by a minimum of 1OOmm Fibre Glass mesh 165 gm weight minimum 5 x 5 mm aperture Dulux AcraTex Renderwall P400 Finishing coat Renderwall P400 Apply finishing coat of PAOO Renderwall basecoat mixture to completely cover and encapsulate the mesh with a minimum of 2mm cover Finish the PAOO BOO IBasdismell Renderwall base coat by lightly scratching the surface to provide a surface DAOAA3 L 7kg m mm key for subsequent levelling or t
28. timber framing from any occasional leaking by providing a gap allowing water to drain down the back of the cladding and out through the base of the cavity Any remaining moisture within the cavity is able to dry through ventilation provided along the bottom edge of the cavity The four key elements of a cavity amp moisture management system e Deflection The first line of defence is a well designed and constructed cladding system to deflect the water away e Drainage A cavity provides a second line of defence by draining away water that may leak behind the cladding e Drying By ventilating the cavity any moisture that has not drained away is removed by drying e Durability Materials for wall and cavity construction must be sufficiently durable to resist decay for a period that will allow time for a leak to be discovered and repaired Dulux Exsulite Trained Installer Network An Exsulite Certificate of Installation from a registered Exsulite Installer provides peace of mind that as built meets Design Specification All Exsulite Trained Installers 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 Exsulite Installer Network ensures Total Facade System compliance From Start to Finish e Installer Training and Ongoing Development e Registration and Verification ID
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