INSTALLATION MANUAL FOR ACEWALL PANELS For Both
Contents
1. Installation Manual for Unfilled Ace Wall Partitions 100mm ACE WALL INTERNATIONAL PTY LTD QUALITY ASSURANCE PRIOR TO PERLTE PLACEMENT Project No Date Building Identification Floor Level Exact Location of Construction Zone Identifying Grids CHECK LIST PRIOR TO HANDOVER Date Description All services are complete Damaged panels noted Damaged partitions have been locally reinforced Ace Wall partitions have been properly braced if required Wall junctions have been positioned and screwed of properly Partitions checked for plumb Formwork has been cut back where required to gain access for filling Site clean of any debris created by installation of Ace Wall partition panels and any other trades Ace Wall partitions for this section are ready for perlite filling Comments Ace Wall Building Supervisor Date Signature Please print name Contractors Representative Date Signature Please print name 27 Revision 1 1NF 25072011 Installation Manual for Unfilled Ace Wall Partitions 100mm ACE WALL INTERNATIONAL PTY LTD QUALITY ASSURANCE FINAL HANDOVER COMPLETION ON FINISHING ACE WALL PARTITION PANELS FINAL INSPECTION PRIOR TO SURFACE COATING Building No Level No All Ace Wall partition panels have been inspected and are free of defects as noted below The Ace Wall partition panels i2. INSTALLATION MANUAL FOR ACEWALL PANELS For Both PARTITION AND EXTERNAL CLADDING Installation Manual for Unfilled Ace Wall Partitions 100mm For further information please contact Mr Bill Wallace Address Ace Wall International Pty Ltd 503 Port Road Croydon West South Australia 5008 Telephone 61 0433 467 931 Fax 61 8 8340 2456 Email info acewall com au www acewall com au Disclaimer This presentation and any accompanying appendices has been prepared by Ace Wall International Pty Ltd Copyright of all material contained in this document is vested In Ace Wall International Pty Ltd whose written permission for the reproduction of any information contained therein must be obtained Care has been exercised in the underlying research in this presentation but Ace Wall International Pty Ltd assumes no responsibility for the accuracy of the Information or the effectiveness of the recommendations contained therein Author Disclaimer The authors of this document and accompanying appendices hereby give notice that the information contained within this presentation is of a confidential nature and may not be disclosed without the prior written permission of the authors No responsibility or liability is assumed by the authors with respect to the accuracy or projected outcomes of the information contained herein Revision 1 1NF 25072011 Installation Manual for Unfilled Ace Wall Partitions 100mm 10 11 12 13
3. EXPANSION JOINTS Ace Wall partition panels manufactured from Gypsum display only minimal coefficients of thermal expansion and contraction compared to heavy weight building materials such as masonry and concrete It is still important to provide for expansion movement joints to allow for overall structure movements and provide for articulated wall design Control joints should be as specified by the architect in consultation with the engineer to suit building appearance Joint materials to be closed cell polyethylene compressible filler strip or backing rod sealed over with construction grade paintable polyurethane sealant The most efficient method for control joints to Ace Wall partitions is at the vertical joint 15 Revision 1 1NF 25072011 Installation Manual for Unfilled Ace Wall Partitions 100mm SETTING STOPPING FLUSHING Ace Wall partition panels require minimal setting stopping and flush finishing when compared to masonry and plasterboard wall construction Once partition panels are installed services placed door and window frames located and roof covered finishing trades can commence Interior finishing The Ace Wall partition panels must be dry clean sound free of contaminants splashes of plaster mortar and sillcone compounds All interior corners joints and wall Intersections to be flushed finished using the following components Paper fiberglass flushing tapes Metal PVC corner angles and bead
4. 10 PAINTING Ace Wall partition panels manufactured from water resistant Gypsum plaster provide the ideal substrate for both interior and exterior paint and texture coat finishes Acrylic water based top coat systems applied over paint manufacturers recommended primer sealer coats produce excellent results General acrylic paint qualities such as bond strength elasticity UV light resistance weather resistance fungus resistance and texture thickness are all important performance qualities of the coating system selected The coatings must also have the ability to breathe and allow vapour permeability while not allowing the ingress of water due to fair particularly important for exterior wall applications EXTERIOR COATINGS Although Ace Wall partition panels are highly water resistant it is still mandatory to provide a suitable waterproof coating system to further reduce the long term weather abrasion effects Exterior finishes must have similar strength and elastic performance to that of the Ace Wall Gypsum material to ensure thermal movements are compatible and cracking and crazing will not occur For this reason cement rich renders should not be used due to their high shrinkage when curing and rigid performance on setting Manufacturers have created a fashionable range of texture coatings offering low and high profile roll on trowel on spray stipple or stucco applied coating systems A great benefit of specifying exterior A
5. 14 CONTENTS WATPOGU CUI OM ss ceeccsdevssssetsstveecescadaasnts ota olesaedie cas E ES ERB Teen Page 4 Planning the Construction cccccecccsscsscssssssscsecseceeceecessesscesescseesececsesessesaeeasees Page 5 Tools and Equipment sse senennrnnzenzenznnaznzannnnantnnt eneret kreere aanAntnntnnnAnznnz ttanta nanna Page 6 Set Out and Preparation ssseseeeenzenzznnznnanmnnnanzantnnnnz tre rna renere nr renser tana na Page 8 Panel Transport 8 Deliverv sess sesenzznnznnanmnznnnenzantnnzanzntannaarnnznanzanznnznnzznznnnaznna Page 10 Panel Ere tiON i is a RSR ERR i Page 11 Installation of Door and Window Frames ssesenenzenzenzenzanmazzantenzznznnznnaznanzna Page 13 SERVICES eee pe se esa ce veda vate ook ev ele sansa E OEE Haase Page 14 FINISNINB a a a a Tees Page 15 Painting AL i a cen heh RE ate cc een WI Page 19 Accessories and Add ONS oa EA ra er ata ana Page 20 Health and Sale ii ii ai a a ites Page 21 Work Method Statement 0 0sesenesnnznzonnennenznzmontenzznznnzanantanranznanznnznnzznzznzztazta Page 23 DFA WINES A E E p a Page 29 Revision 1 1NF 25072011 Installation Manual for Unfilled Ace Wall Partitions 100mm 1 INTRODUCTION This manual has been written as an aid to anyone involved in construction using the Ace Wall partition building system It covers all aspects of the installation process including handling tools services concrete and surface finishing It also show
6. Remove all other temporary supports from walls and floor and leave area clear for follow on trades 8 02 Note condition of walls especially after perlite placement and notify relevant party to final sign off Stage Nine 9 01 Flushing of all joints using the recommended products 9 02 Once all joints have received the required coats and are completely dry then they are sanded to a smooth finish 9 03 The wall system is now complete to receive final finished by others Stage Ten 10 01 SIGN OFF BY SUPERVISOR AND BUILDER IS NOW REQUIRED 25 Revision 1 1NF 25072011 Installation Manual for Unfilled Ace Wall Partitions 100mm ACE WALL INTERNATIONAL PTY LTD QUALITY ASSURANCE PRIOR TO COMMENCEMENT SETOUT Project No Date Building Identification Floor Level Exact Location of Construction Zone Identifying Grids CHECK LIST PRIOR TO ACEWALL PARTITION PANEL INSTALLATION Item Details N A Complete Incomplete 1 Floor slab level 2 Under floor slab level 3 Product onsite and in good condition 4 All grid lines clearly identify wall locations 5 All door and other openings identified 6 All floor and ceiling penetrations are in correct locations 7 Handover construction area to installers Comments Ace Wall Building Supervisor Date Signature Please print name Contractors Representative Date Signature Please print name 26 Revision 1 1NF 25072011
7. accessories Paintable acrylic sealants Approved flushing plasters and skim coats Exterior finishing The Ace Wall partition panel must be dry clean sound free of contaminants splashes of plaster mortar and Silicone compounds All exterior corners joints and wall Intersections to be flushed finished using the following recommended exterior grade components Fibreglass flushing tapes Rigid PVC corner angles and bead accessories Exterior construction grade paintable polyurethane sealants Approved flushing plaster setting cements with water resistant acrylic bonding additive Do not use any other retarders or accelerators in the mixture For both exterior and interior filling and flushing good quality plaster based setting cements should be used and not powder or pre mixed air dried compounds The use of approved acrylic bonding additives in the liquid gauge plaster mixture at specified ratios will provide greater workability water resistance bonding and joint strength 16 Revision 1 1NF 25072011 Installation Manual for Unfilled Ace Wall Partitions 100mm CORNICE amp SKIRTINGS Cornices if required are fitted in the conventional manner using cornice adhesive Consideration should be given to installing a larger 90mm cornice to enhance the 2 7m high walls Standard 55mm cornice can be used also or replaced with a shadow line flushed wall ceiling detail to create a contemporary clean appearance Timber skirting c
8. medical attention Wash with warm water and mild soap Remove to fresh air If any ill effect persists seek medical attention 21 Installation Manual for Unfilled Ace Wall Partitions 100mm e ADVICE TO DOCTORS Treat symptomatically e PRECAUTIONS FOR USE No special precaution necessary e PERSONAL PROTECTION None required for normal use but if cutting ACE WALL with an electric saw a nuisance dust mask eg 3M brand mask 8500 is recommended and goggles advisable e SPILLS No special precautions e DISPOSAL Dispose of as normal waste subject to conforming to state e PHYSICAL DESCRIPTION AND PROPERTIES Gypsum plaster core reinforced by fibreqlass strands Specific gravity H20 1 0 0 7 Solubility in water 0 2 Non flammable Non hazardous e FIRE Ace Wall partition panel is non combustible Extinguish local fires with water CO2 etc No special fire fighting procedures required 22 Revision 1 1NF 25072011 Installation Manual for Unfilled Ace Wall Partitions 100mm 13 Work Method Statements f g b c d f g h j k ACE WALL INTERNATIONAL PTV LTD SAFETV PROCEDURES FOR ERECTION OF ACE WALL PARTITION PANELS Definitions Ace Wall partition panels anv 100 mm thick section of fibre reinforced plaster wall Manufactured using Ace Wall Technologv Lifting clamps lifting clamps used to lift Ace Wall partition panels Hand trollev steel frame on casters designed to move Ace Wall partiti
9. providing 311m2 of panel area to be delivered at one time The use of a truck crane for suitable projects can provide the delivery and on site unloading of the partition panels Affordable delivery costs can be achieved to remote areas by bulk delivery of partition panels from the factory to site HANDLING Lifting loading and general handling of the Ace Wall partition panels can be achieved using conventional and affordable specialised systems Lifting of pallets can be achieved using fork lifts cranes and truck cranes Ace Wall partition panels can be moved unloaded and installed using all the above mentioned equipment Being lightweight all partition panels can be installed manually or by using a number of specially built trolleys hand trucks and hand frames A minimum of 9 people not including the crane operator should be involved in an Ace Wall partition panel erection team 2 for the setout 2 for the placement of bottom track and top plate 2 for the placement of partition panel 1 for cutting and cleaning 2 for flushing 10 Revision 1 1NF 25072011 Installation Manual for Unfilled Ace Wall Partitions 100mm 6 PANEL ERECTION POSITIONING PARTITION PANELS Start with the set out marking out locations for walls doors and openings from the architects or engineers drawings is essentially one of the most important functions Once this is done the fixing of bottom tracks and top angles where required is carried out and when
10. switches 90 set out angle square large spirit level set out string lines chalk lines and accessories measuring tapes marking pens pitch bars step ladders saws Electric and Hand held Safety equipment boots hard hat dust masks eye protection ear protection and sun protection For remote projects without electrical power a small petrol generator will enable all power tools to operate Revision 1 1NF 25072011 Installation Manual for Unfilled Ace Wall Partitions 100mm 4 SET OUT AND PREPARATION SETOUT Initial floor slab checking for correctness of size shape and level should precede wall panel installation Should any major tolerance problems be evident the builder will require notification to rectify Wall locations are set out using chalk lines and marking pens to clearly indicate installation location Also accurately and clearly mark the location of doors and windows to prevent the fixing of floor tracks at these positions FLOOR TRACK LOCATION SYSTEM For Ace Wall partition panels specially designed floor tracks are first secured to the slab using masonry anchors Ace Wall partition panels are then installed self locating over the floor tracks to achieve a neat appearance between the wall panel and floor slab TOP ANGLE During the setting out process when the location of the bottom floor track is marked it is then by the use of a laser beam that the underside of the slab is also marked A 50mm x 50mm x fro
11. this procedure is complete we are now ready to position and install the Ace wall partition panels It is also important that the positioning of full pallet loads of Ace wall partition panels are as close as possible to the working location e From the pallet 1 panel at a time is placed onto a hand trolley if required and moved to its correct location if cutting is required it is carried out before moving from the pallet e Position the starting mould At its correct location the Ace wall partition panels is lifted to its upright position then by the use of the lifting clamps it is placed onto the bottom track and against the top angle Be sure not to slide the Ace wall partition panel against the starting mould until the adhesive has been applied e Apply the adhesive to either the starting mould joint or Ace wall partition panel joint then slide and lock them together use tek screws through the top angle for extra locking if necessary Further top angle pieces are placed at the opposite joints to further lock into place e The above process is continued until work is complete e ifthe cores are to be filled with perlite then no further work to the surface of the wall is carried out until services and perlite filling has been completed e ifthe cores are to be left empty then the taping and flushing of each vertical joint can be carried out This is sanded once dry and the wall is now ready for painting CARE OF THE WALL SURFACES BETWEE
12. N THE FINISHING TO PAINTING NEEDS TO BE OBSERVED PACKERS Ace Wall partition panels may require packing due to unevenness in the slab Small strips of solid fibre cement or plastic sheet provide stable packers enabling panel bottoms and wall intersections to be correctly plumbed and leveled prior to locking in 11 Revision 1 1NF 25072011 Installation Manual for Unfilled Ace Wall Partitions 100mm WALL amp PANEL CONNECTIONS During the site cutting process timber UPVC or steel closure studs are installed at the panel ends to duplicate a vertical rib to provide strength and a site fixing system Timber UPVC or steel closure studs can be installed on site and simply screw fixed through the panel into the stud Abutting corner and cross walls are positioned propped aligned leveled and then can be screw fixed using large 150mm long tek screws through the closure studs to produce a permanent strong connection These must be exterior grade treated screws This connection procedure allows for rapid and immediate Installation of the partition panels to minimise on site construction time manpower and propping costs The use of closure studs and screw fixings can also provide strong connections 12 Revision 1 1NF 25072011 Installation Manual for Unfilled Ace Wall Partitions 100mm 7 INSTALLATION OF DOOR AND WINDOW Window and door frames of any size and type steel timber or aluminium frames may be fitted within the system T
13. an be secured by glue fixing with cornice cements or construction adhesives with tek screw nailing or PVC spaghetti nail fixing to provide initial support until curing of the glue Vinyl skirting and seamless floor coverings can be contact glue adhered as per manufacturers recommendations FIXINGS AND FASTENERS Fixing to the Ace Wall partition panels can be considered as similar to other types of cellular drywall or plasterboard material Many brands and fastener types can be used and manufacturer s recommendations should be followed for Installation and allowable loading Capacities The unique Ace Wall panel with cavity construction and vertical ribs at 300mm centres does not allow for nail or screw fixings without the use of void filling materials such as timber UPVC or steel closure studs backing plates and solid concrete or grout filling By pre planning critical load fixtures at construction stage void filling installation procedures will allow conventional fastener systems to be installed This is only necessary for heavy weight fixtures and loads exerted by cantilever hand basins troughs brackets wall plates and industrial cabinets etc In general light and medium weight fixtures can be attached with a variety of hollow cavity wall fasteners Fixing through the ribs although acceptable is not generally done because fixture installations are restricted to rib locations Chemical injection anchor systems can also be used to carry
14. ce Wall partition panels is the superior surface flatness requiring less demanding applied coating hiding power Acrylic textures masonry and elastomeric paint systems can offer affordable coating solutions while still providing weather resistance and enhanced appearance A combination of the coating product selected colour and method of application will enable the designer to vary the final appearance function and costing of a project Ace Wall may need to be primed with an appropriate approved primer Make sure that this primer is applied according to specifications and that particular care is taken along the edges of the panel sections A variety of approved paint finishes from Acrylic house paints to architectural texture coatings may be used on the panel At all times follow the manufacturer s specifications 19 Revision 1 1NF 25072011 Installation Manual for Unfilled Ace Wall Partitions 100mm 11 ACCESSORIES amp ADD ONS The builder developer owner may wish to express individuality in the dressing up of the basic Ace Wall building system This can take the form of window and door reveals quoins and plinths Exterior profiles once installed require texture or paint finishing to further enhance the buildings appearance and provide increased weather durability Stone slate brick plinths and tile facings can also be installed to the wall panel along with roof tile slate or iron roofing overlays to create the tradit
15. ck pallets one upon another for craneage and removal to nominated storage area 24 Revision 1 1NF 25072011 Installation Manual for Unfilled Ace Wall Partitions 100mm Stage Four 4 01 Cut and place door and window heads and fit either steel or timber studs to underside Stage Five 5 01 Fit temporary propping to all openings if required Stage Six 6 01 On completion i e floor by floor basis check all partition panels located in correct position and thev are both true and plumb and braced check that installation of beams has not moved partition panels out of plumb 6 02 Check all openings i e door window is in correct location and where required braced and supported to receive perlite Stage Seven if required 7 01 Perlite Filing Brief pump operator as to the required specified slump and expected volume of perlite to be placed 7 02 Do not commence filling if other than Light discontinuous rain is likely 7 03 If rain occurs then attempt to complete filling partition panels to full height if possible and block panel openings to prevent ingress of moisture 7 04 Wash down any perlite spillage before it hardens Stage Eight 8 01 On completion of floors being constructed with Ace Wall partition panels carry out the following Remove temporary braces of walls stack and relocate to the next level Remove temporary supports from door and window openings after sufficient curing period where perlite filling has taken place
16. he system also offers special details for interior and exterior reveals to enhance the building appearance Doors and window openings are generally left out on site during panel installation to accurately profile the door or window frame the remaining head panel section will act as a lintel transferring any loads to the panel sides without loading up the door or window frame However in the case of large openings over 1 5m wide it may be necessary to install a lintel beam and posts within the Ace Wall cavity cores to carry the overhead load In this case a panel off cut can be cut to fit around the lintel to form the head panel or base panel Timber UPVC or steel closure studs screw fixed within the cavity cores provide the securing mechanism for fixing door and window frames The installation of the closure studs takes place on site after the openings are left Use exterior grade screws Timber and steel door frame styles are commonly specified both simply installed by the installation or carpenter contractors When ordering door frames care should be taken to specify the frames to suit the Ace Wall panel thickness of 100mm to ensure correct fitting over the panel Fire door applications can be achieved by using steel closure studs steel door frames and fire resistant void filling grouts The use of standard 3 piece knock down steel door frames allows for efficient installation handling and transportation costs Window frames comm
17. heet 16A steel door frame Detail Sheet 17 steel door frame Detail Sheet 18 galvanised stud to timber door frame Detail Sheet 18A UPVC stud plate to timber door frame Detail Sheet 19 galvanised stud to aluminium window frame Detail Sheet 19A UPVC stud plate to aluminium window frame external no cavity Detail Sheet 20 galvanised stud to timber window frame Detail Sheet 20A UPVC stud plate to timber window frame external no cavity Detail Sheet 22A UPVC external rebate non load bearing wet area set down no cavity Detail Sheet 23 wall ties Detail Sheet 24 wall ties Detail Sheet 25 external application non load bearing no overhang cavity Detail Sheet 29 external application non load bearing with overhang Detail Sheet 30 wet area detail shower Detail Sheet 31 wet area detail prefabricated shower base bath spa housing Detail Sheet 32 wet area detail bidet pan wall hung canterliver Detail Sheet 33 wet area detail vanity unit wall hung canterliver Detail Sheet 34 wet area detail vanity unit wall hung canterliver Detail Sheet 35 wet area detail plumbing hardware penetration Detail Sheet 36 electrical detail surface mounted Detail Sheet 37 electrical detail recessed Detail Sheet 38 general fixing detail 29 Revision 1 1NF 25072011
18. ices Shrubs trees and overhanging branch restrictions Revision 1 1NF 25072011 Installation Manual for Unfilled Ace Wall Partitions 100mm 3 TOOLS AND EQUIPMENT CUTTING amp FABRICATION Ace Wall partition panels can be cut using conventional woodworking hand and power tools as appropriate Gypsum being the base material can be sawn drilled screwed and nailed Cutting partition panels to size can be undertaken on site Secondary fabrication such as Gypsum timber UPVC or steel closure studs fixing can be achieved using conventional tools and a range of fixing systems HAND TOOLS Ace Wall partition panels can be cut and trimmed using any of the following hand tools timber or gyprock hand saw keyhole saw rasp trimming knife and hand sanding floats POWER TOOLS Ace Wall partition panels can be cut and trimmed using conventional woodworking power tools circular saw reciprocating saw chainsaw jigsaw power sander and angle grinder PROPPING if required The use of a simple propping system allows Ace Wall partition panels to be installed in an efficient and safe manner The basic prop consists of a square hollow section tube with a pivoting top support bracket and bottom anchoring plate The top support bracket is simply placed over the top of the panel at a rib location for maximum support the panel alignment and plumb checked then anchored to the floor through the bottom plate As the installation procedure progresses c
19. ional look Verandahs carports garages shade and porch hoods and pergolas become add on attachments either as part of the original design or future planned extensions 20 Revision 1 1NF 25072011 Installation Manual for Unfilled Ace Wall Partitions 100mm 12 HEALTH AND SAFETY None of the three basic components of Ace Wall plaster fiberglass and water presents a health hazard Plaster the basic ingredient of Ace Wall has long been used as filler in medicines and is a major component of toothpaste The fiberglass component of Ace Wall is non respirable The chemicals used are used in small volumes and present no health hazard in the finished product SAFETY DATA e IDENTIFICATION Plasterglass panel composed of a gypsum plaster reinforced by filimatised fiberglass e USE Structural building panel for interior and exterior use e INGREDIENT Gypsum Fibreglass Water Repellent CONTAINS NO ASBESTOS e HEALTH EFFECTS Swallowed Eye Contact Skin Contact Inhalation e FIRST AID Swallowed Eye Contact Skin Contact Inhalation Revision 1 1NF 25072011 98 0096 1 096 1 096 No adverse effects known Minor Irritation Can Irritate largelv confined to cutting trimming and grinding operations Mav cause minor irritation Dust masks mav be beneficial in areas where high dust levels occur Give plentv of water to drink Wash with running water using eve bath or wash bottle if irritation persists seek
20. m 0 75mm continuous angle is fitted to be able to receive the top of the Ace Wall partition panel for fixing Once Ace Wall partition panel is in place a short piece of angle is then used at the joint location to lock panels in place Revision 1 1NF 25072011 Installation Manual for Unfilled Ace Wall Partitions 100mm PRE PANEL ERECTION CHECKLIST Before commencing erection of Ace Wall partition panels check that all relevant items of the following checklist have been taken care of Set out completed All floor tracks in on site Water proofing foam if applicable Crane and or hand trolleys organised Accessibility of site checked No overhead power cables Tools on site Sufficient props on site Fixing consumables on site Top angle plate on site Power available Lifting clamps on site Slab accuracy checked Accurate architectural drawings available including kO 00 ds OY IND 3 bbhkb BWNR OO Panel layout location of door and window openings schedule of reveals etc flashing details location of services O lt Q 10 gt 100 15 Relevant engineering drawings available Revision 1 1NF 25072011 Installation Manual for Unfilled Ace Wall Partitions 100mm 5 PANEL TRANSPORT amp DELIVERY Ace Wall partition panels are horizontally loaded onto purposely formed pallets ready to be picked up by the appropriate transport vehicle Up to 144 full size partition panels can be loaded onto a semi trailer
21. medium to heavy loads in situations where walling and building work has been completed Revision 1 1NF 25072011 17 Installation Manual for Unfilled Ace Wall Partitions 100mm TILING Tiles can be directly laid onto the panel face in the conventional manner Proprietary pre mixed flexible tile adhesives perform best over traditional on site sand and cement mixed grouts WET AREAS Wet area design and specifications must comply with the relevant government building standards As for conventional materials design and construction details need to be observed for the critical shower alcove area By using water resistant Gypsum panel constructions details are simpler than other lightweight plasterboard walling products Shower area floors need to be waterproofed by the installation of an accredited insitu shower tray membrane system or a proprietary shower base The shower tray membrane must carry up the wall sides and bonded to the Ace Wall face The membrane should be carried up the full height of the tiling to provide extra shower wall protection All remaining wall surfaces in a wet area must be suitably paint finished to provide moisture protection and enhance appearance WALLPAPER All walls should be sized prior to hanging wallpaper and normal decorating practice should be followed in conjunction with the manufacturer s instructions 18 Revision 1 1NF 25072011 Installation Manual for Unfilled Ace Wall Partitions 100mm
22. n this area are ready for painting Ace Wall Building Supervisor Signature Date Please print name Contractors Representative Signature Date Please print name Ace Wall Building Supervisor Signature Please print name Contractors Representative Signature Date Please print name Distribution 1 Ace Wall International Pty Ltd Revision 1 1NF 25072011 2 Client s Representative 28 Installation Manual for Unfilled Ace Wall Partitions 100mm 14 Drawings LO COS OT et FR NNNN RPP PB OMBWNHPRP OW WON DU HRWNPF OO 26 27 28 29 30 31 32 33 34 35 36 37 38 Typical Panel Detail ACC 1 Typical Panel Accessories ACC 2 fixing plate and angle Typical Panel Accessories ACC 3 channel Typical Panel Accessories ACC 4 stop ends and starter Typical Panel Accessories ACC 5 UPVC bottom fixing plate Typical Panel Accessories ACC 6 stud plate opening flashing Detail Sheet 1 bottom fixing Detail Sheet 2 top fixing Detail Sheet 3 vertical butt joint and panel flushing Detail Sheet 4 vertical butt joint alternative Detail Sheet 5 external corner when used for internal partition Detail Sheet 6 external corner when used for cladding Detail Sheet 7 expansion joint Detail Sheet 8 expansion joint Detail Sheet 9 expansion joint Detail Sheet 16 steel door frame Detail S
23. on panels across firm level surfaces Tek screws metal fasteners with thread used to join two sections of wall partition panels together Steel Prop 50 x 50 section of steel with a speciallv designed steel hook on one end and flat steel plate on the other end can be used to stabilise wall partition panels during erection stages Ace Wall transport pallet speciallv designed plastic transportation pallet Safetv procedures Ace Wall transport pallets must alwavs be placed on level ground and where not possible blocks must be placed to make sure the pallet with partition panels is totallv level During erection of Ace Wall partition panels all work shall be carried out in a tradesman like manner with particular consideration for the safetv of all personnel Where Ace Wall partition panels are moved with the use of a hand trollev wind conditions must be taken into consideration Partition panels must never be left unattended on a hand trollev All personnel are to avoid standing underneath a panel being lifted If steel props are used thev must alwavs be connected to the panel bv placing the clamp over a rib and all steel props must be firmly secured to the floor The supervisor shall ensure that all erected walls are safelv braced or propped correctly at completion of each work shift before leaving the site When partition panels need to be cut on site a dust mask needs to be worn of a minimum P2 standard When cutting or sanding parti
24. onfirm delivery date time and panel schedules Stage One 1 01 Identify and mark panel numbers on floor set out 1 02 Measure and mark floor slab to accommodate services and transfer set out details from Ace Wall Panel Schedule to accommodate same 1 03 Provide continuous blocking to floor slab on one side of wall only if required 1 04 Set out and mark all door and window locations 1 05 Complete set out to enable 100 of Ace Wall partition panels to be erected in any given area Stage Two 2 01 Drill holes in floor track at predetermined centres to accommodate services 2 02 Remove dust residue 2 03 Place floor track and top angle 2 04 Place yellow safety caps over services not required if done simultaneously with panel erection Stage Three 3 01 Determine method of lifting panel from pallet 3 02 Ensure ona daily basis that the lifting clamps are in good working order prior to start of day s lifting 3 03 Reference to Ace Wall Cutting Schedules and pallet loading for order for placement of partition panels 3 04 Position brace for Ace Wall panel vertical and temporarily secure to floor slab via a 10mm dia x 40mm dyna bolt ensuring true plumb and alignment if required Ensure panel is level and shim where necessary to bring in to level plane 3 05 Drill and place 150mm Hex Head 14 gauge screws at intersection of adjoining walls at 600mm centres if required 3 06 On completion sweep and place all offcuts and debris in waste bins provided 3 07 Sta
25. only specified are aluminium or timber styles depending on the desired building look or construction type both these frame methods can be installed into single leaf Ace Wall construction or veneer double leaf construction Location of the frame position within the Ace Wall panel can provide many combinations of exterior and interior reveal finishing off details Attention to these details at the design stage will enhance the overall building appearance and costing Conventional timber fibre cement sheet or masonry materials can be utilised The use of external flange aluminium window extrusions with the flange sealant fixed to the Ace Wall partition panels exterior face can provide a fast and cost effective solution eliminating all exterior reveal moulds 13 Revision 1 1NF 25072011 Installation Manual for Unfilled Ace Wall Partitions 100mm 8 SERVICES The installation of plumbing electrical and other cable services throughout the building is verv similar to current building practice For single leaf Ace Wall construction all plumbing and electrical services are tvpicallv run horizontally along the top of wall or roof system members then vertically down the panel cavities without any nogging restrictions Services are best installed once all Ace Wall partition panels are positioned and locked in and alterations can take place after these operations with minimal inconvenience Fixture fittings and tap assemblies are easily cu
26. pplications ranging from affordable housing commercial industrial buildings and multi storey apartments Preliminary contact between the engineering and architectural consultants client and the Ace Wall supplier will ensure the building system is designed to suit specific project requirements in terms of structural adequacy fire ratings acoustic thermal performance costing and appearance Efficiency in design construction and cost savings are maximised by the early assessment and specifying of Ace Wall partition panels in the project planning stage Ace Wall can be fabricated to provide a fast and efficient on site construction system Fabrication schedules are manually or computer generated to suite each project Effective pre planning and fabrication at the factory can overcome expensive on site delays and provide fast track construction solutions Should the need arise to cut and fabricate partition panels on site this can be easily achieved using conventional hand and power tools Window and door openings are usually cut out on site during the installation of the partition panels It is important to emphasise to the people responsible for slab set out and construction that dimensional accuracy is very important to successfully installing the Ace Wall partition panels BEFORE DELIVERY SITE ACCESS NEEDS TO BE ADDRESSED Terrain conditions All weather access roads for delivery trucks and crane Overhead power cables and underground serv
27. ross and corner walls are secured to each other and the props can be gradually removed Depending on wall lengths and heights it is possible to completely remove all propping at the completion of the last wall panel This reduces greatly the number of props required for a project and saves time in the recovery of the propping system at a later date e When erecting Ace Wall partition panels without top support place props every 4 m e Maximum un propped length of Ace Wall partition panel between cross walls and or corner connections is 4 m LIFTING CLAMPS Purpose designed and made handheld lifting clamps enable quick and safe lifting of the partition panels into position The lifting clamps can be positioned on the tongue and groove section of the Ace Wall partition panel Once located in place the clamps are tightened allowing safe pick up and placement Ace Wall partition panels up to 3 6 meters high can be lifted using two clamps e Maximum panel height lifted with two handheld lifting clamps is 3 6 m Revision 1 1NF 25072011 Installation Manual for Unfilled Ace Wall Partitions 100mm GENERAL INSTALLATION TOOLS Once again a range of general woodworking tools as typically used by a carpenter will enable complete installation of the Ace Wall partition panels in particular the following list would be required Heavy duty drill Electric and Cordless 2 tek screw guns laser level hammer extension leads with earth leakage safety
28. s a number of standard details for various applications it is important to study these drawings prior to commencement of work on site Ace Wall partition panels are made from Additives PARTITION PANEL SIZE amp SPECIFICATION Gypsum plaster Calcium Sulphate Hemihydrate Fibreglass Clean water Size Available Width 600 mm 600Omm 600Omm 600mm 600mm 600mm Size Available Height 2 1m 2 4m 2 7m 3 0m 3 3m 3 6m Size Available Thickness 100mm 100mm 100mm 100mm 100mm 100mm Panel area m2 1 26 1 44 1 62 1 8 1 98 2 16 Approximate weight per square metre 38 kg 38 kg 38 kg 38 kg 38 kg 38 kg Approximate full panel weight 47 784 kg 54 611 kg 61 437 kg 68 263 kg 75 09 kg 81 916 kg Number of cavity cores per full panel 3 3 3 3 3 3 Volume of one cavity core m3 amp litres 0 028 28 0 032 32 0 036 36 0 040 40 0 043 43 0 047 47 Volume of full panel cavity core m3 amp litres 0 083 83 0 095 95 0 107 107 0 119 119 0 130 130 141 142 Volume of cavity cores per m2 m3 amp litres 066 66 066 66 066 66 066 66 066 66 066 66 Revision 1 1NF 25072011 Installation Manual for Unfilled Ace Wall Partitions 100mm 2 PLANNING THE CONSTRUCTION Ace Wall partition panels can be utilised in numerous construction applications and provide outstanding solutions for project a
29. t and chased into the Ace Wall outer skin with standard woodworking tools and simply mounted onto a timber block screw fixed to the panel To minimise horizontal cutting chasing and associated repair work it is recommended that loop and branch lines not exceed approximately 1 m horizontally Repair work is undertaken after completion of all fixtures and fittings by wadding up the panel Wadding a stiff mixture of plaster and fibre glass rovings placed around the penetration sets and bonds to all in contact providing a permanent fixing ready for final flushing or tiling Care should be taken to eliminate water pipe hammer as per normal procedure Alternatively the use of polybutylene plumbing systems will eliminate water hammer and it integrates well with the Ace Wall building system Plumbers electricians and others will find many benefits in working with Ace Wall over other forms of solid construction resulting in labour savings to the builder developer Important Any pipework needing pressure testing must be carried out prior to filling the walls 14 Revision 1 1NF 25072011 Installation Manual for Unfilled Ace Wall Partitions 100mm 9 FINISHING Architectural specifications will list the following Specify coating type and application method and colour Exterior waterproof finish Interior decorative finish Tile slate or stone facing Architectural profile quoins and corner sections Location of expansion joints
30. tion panels on site with the use of power tools a dust mask needs to be worn of a minimum P2 standard as well as suitable eve protection A safety hard hat must be worn by all personnel on site during lifting and placing of Ace Wall partition panels Before the end of each work shift anv off cuts of partition panels are to be placed in a suitable container and all dust is to be wet swept or dry vacuumed and placed ina covered container Dust and off cuts are to be disposed of in accordance with the relevant local authoritv s waste disposal requirements and regulations Note In the event of timber UPVC or steel studs being inserted into the cavitv of an Ace Wall Panel under no circumstances shall lifting devices be attached to these studs for lifting purposes All lifting devices shall be attached to solid ends of Ace Wall Partition panels 23 Revision 1 1NF 25072011 Installation Manual for Unfilled Ace Wall Partitions 100mm ACE WALL INTERNATIONAL PTY LTD WORK METHOD STATEMENT FOR PLACEMENT OF ACE WALL PANEL SYSTEM Preliminary Requirements e Clear slab of ponding water if applicable e Establish datum for floor and note floor level to be 5mm from specified reduced level e Mark grid lines for set out from established survey grid provided by client e Clear slab of debris and equipment by others e Position indicators at int ext corners and reference location points e Confirm method of placement of partition panels e C
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